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Model FC400G Free Available Chlorine Analyzer (Non

1. u D Item Part No Qty 1 1 1 1 1 2 A1111EF 1 CMPL 12F05A01 01E i MW it Wy Description Converter for Model FC400G 65 to 68 A Converter for Model FC400G 55 to 58 A Converter for Model FC400G 65 to 68 A PPM Converter for Model FC400G 55 to 58 A PPM Fuse 2A 7th Edition Jun 2011 YK Part No L9804UK 2 a K9332JP K9334VA 3 nes K9334JY K9334VQ K9334VR K9334VS 4 K9334LK K9332JS K9334LP K9334KD K9332J5X K9332JZ K9334LM K9334LL K9332MK OMAN DYN K9332MB K9334JP k k eS 7th Edition Jun 2011 YK DETECTOR 33 32 31 30 a ae eee ae ee a 27 28 26 24 25 22 23 Description Drive Belt Gear Head For AC 100 110 V power supply For AC 200 220 V power supply Motor Assembly For AC 100 V power supply For AC 110 V power supply For AC 200 V power supply For AC 220 V power supply Capacitor For AC 100 V power supply For AC 110 V power supply For AC 200 220 V power supply Cable Brush Ring Plate Plate Counter Electrode Indicator Electrode For general typ
2. F5 4e ai IM 12F5A1 01E 5 3 3 5 3 4 lt 5 Key Operation and Display gt 5 5 Mode Selection in the Operation Level To enter from the measurement mode to another mode in the operation level or to return from any mode to the measurement mode press key In the operation level the FC400G can return from any status to the measurement mode except in the following cases 1 During calibration mode selection is not accepted until calibration ends 2 In hold status after completion of calibration lt HOLD gt is selected Example i LL HOLTON Not in hold status In hold status YES Note Pressing the C_D key allows the hold status to continue F5 3 3e ai Transfer to the Setting Level Unscrew four fixing screws to remove the converter case cover Press the key to select the setting level from measurement mode To return from the setting level to the measurement mode in the operation level press the or key However if the FC400G is in the hold status transfer to the measurement mode is disabled the FC400G returns to the lt HOLD gt mode Note The key is available only when the FC400G is not yet in any mode in the setting level Example HOLION MODE CM Note 1 Note CD is not available F5 3 4e ai IM 12F5A1 01E 5 6 lt 5 Key Operation and Display gt 5 3 5 Transfer to the Service Level Press the key to select the
3. 5 7 5 4 1 Mode Selection in the Operation Level ccceccceeeeeeeeeteeeteeetees 5 7 5 4 2 Modes in the Setting Service Level and Selection of TNE SOUING tems sri a eie el eG Ga 5 11 OPER ATION sicsieticditesenstasiastalinticenasiasianininsieinamenatinnntnnaaiats 6 1 6 1 Preparation for Operation siiccscccncescceceseccuedecsstcnceseeseectesceceetseesceceueteentceesnesesecece 6 1 6 1 1 Inspecting Piping and Cable Installation Condition eee 6 1 6 1 2 Filling with Ceramic Beads for Electrode Polishing e ceeee 6 1 6 1 3 Supplying Sample Water cccccececeeceeeseeeeseeeeeeaeeseneeeeneeeseeeetees 6 2 6 1 4 Polishing the Indicator Electrode ecceceeeeeeeeeeeeeeeeeeeeeeeeeeeneeenes 6 2 6 1 5 SUPPLYING POWE veseveetesieest cast cneteaiaasiier ines aere E EENE audi 6 3 6 1 6 Checking Electrode Mechanism BIOCK ccceceeseeeeeteeneeeneeees 6 4 6 1 7 Filling Zero Water and Test Operation cccceeeseeeeeeeeeeeeeeeeees 6 4 6 1 8 Setting Operation Parameters iiicccccccccccccdecceteceesceseveseceseeusecneeceecevecs 6 4 6 1 9 Calibration 42 2 tat cai E malaria ae 6 4 6 2 Normal Operration ccsccscsccecessesseseseeeeseseeseneeneneeseeseeeseenaeseeseeeneeneeseeeseenenaes 6 5 6 2 1 Maintenance during Normal Operation ecceeeeceeeeeeeeeeeeeneeeees 6 5 6 2 2 Shutting Down then Restarting Operation ceeeeeeeeeeeeeeeeteeees 6 5 6 3 Requirements for Se
4. Converter Unit mm Detector Fc40o0G n di l N oO i A A k g O lt Sample gt water inlet Drain outlet VP16 pipe E VP40 pipe PVC tray i ji op z a kea T y FE T S s 530 385 150 PR1 Pressure reducing valve 455 NV1 Needle valve BV1 Ball valve 550 F3 1 2 ai Figure 3 1 Example of ST401G FC4 Installation IM 12F5A1 01E 3 2 lt 3 Installation Piping and Wiring gt 3 2 Piping 3 2 1 For Use without a Sampling System When sample has a pressure of 1 to 150 kPa and a flow rate of 0 1 to 2 5 I min such sample can be directly introduced into the measuring tank Connect a 6 X 4 mm polyethylene tube to the sample water inlet Connect a 22 X G15 mm flexible mesh reinforced tube to the drain outlet from the measuring tank Install this tube so that no water entrapment is formed Entrapment of water in the drain tube may cause overflow from the measuring tank 2B Pipe Stanchion Gr oO O Electrical connections JIS A15 plastic water gd Measuring tank proof plug or equivalent Needle valve Sample inlet Drain outlet Re 1 4 O22 x G15 mm hose coupling F3 2e EPS Figure 3 2 Free Available Chlorine Analyzer Piping Connections IM 12F5A1 01E lt 3 Installation Piping and Wiring gt 3 3 3 2 2 For Use with Dedicated Sampling System Piping is connected to the measurement liquid inlet and drain outlet The pi
5. Before starting to supply water to be measured confirm that the needle valves in the FC400G and the sampling system are closed When it s difficult to view the liquid surface in the measuring tank from outside check the tank when it s time for electrode maintenance refer to Figure 6 3 1 When there is no Sampling System The sample supply pressure to the FC400G should be 1 to 150 kPa and flow should be 0 1 to 2 5 l min Next slowly open the needle valve of the FC400G to adjust the water flow The water should flow continuously along the whole length of the electrode from the tip to where it enters the water minimum flow 0 1 l min e Liquid flow should not be such that water splashes on the base of the electrode maximum flow 2 5 I min Check that there is no leakage from the piping or from the breather hole of the tank 2 When the FC400G is used with ST401G Sampling System The sample supply pressure should be 100 to 750 kPa and flow should be 0 1 to 10 I min Adjust flow using needle valve as described in 1 above Note Refer to the Instruction Manual IM12A0V2 E of the ST401G Sampling System 6 1 4 Polishing the Indicator Electrode The electrode surface of the indicator electrode must always be kept clean Polish the electrode surface as follows 1 Press the key on the converter to enter the operation level and press the key to select the lt CELL gt mode cell motor ON OFF Press the key with respect
6. In maintenance position Electrode mechanism block Counter electrode reference electrode The bottommost notch of the beads case Indicator electrode rotating electrode Fixing screws 2 pcs 2 pes Beads case Ceramic beads Beads case cover F6 1e ai Figure 7 1 Electrode Mechanism Block in maintenance 3 Select lt CAL gt mode ZERO displayed on message display Note If Service Level code 08 is set to 1 for initialize electrode sensitivity then placing the unit in lt CAL gt mode results in NO CHNG or CHANGE being displayed In response see Sec 7 3 press the key and ZERO is displayed 4 Perform zero calibration Check that the data displayed on the data display has stabilized then press the key While calibration is being performed a blinking mg l or ppm is displayed When calibration ends normally ZR END is displayed Note During calibration if an abnormality occurs then END E6 or END E7 are displayed Refer to Sec 7 4 for a description of how to fix the problem 5 Exiting zero calibration IM 12F5A1 01E Confirm that a normal ZR END rather than an error message then press the key Pressing the key switches the display to SPAN After stopping the indicator electrode revert the electrode to its position in the measuring tank After fixing the electrode mechanism block to the measuring tank restart electrode rotation Perform
7. ST integration into ST401G sampling system must be specified Note 2 pH sensor pH holders pH converter Ultrasonic oscillator Note 3 Note 4 Note 5 Note 6 PF4 or PF5 Note 7 with this option 2 3 3 Spare Parts 4 wire type pH converter system refer to GS 12B7C1 E GS 12B07C05 01E GS 12B07B02 E GS 12J05C02 00E PH8EFP 03 TN TT1 N T A when suffix code of PH4 PF4 specified PH8EFP 03 TN TT3 N T A when suffix code of PH4 PF4 and option code of TT3 specified PH8EFP 03 TN TT 1 N G A when suffix code of PH5 PF5 specified PH8EFP 03 TN TT3 N G A when suffix code of PH5 PF5 and option code of TT3 specified PH8HF PP JPT T NN NN A without cleaning system PH8HF S3 JPT T NN NN A without cleaning system PH8HF PP JPT T S3 C1 A with ultrasonic cleaning PH8HF S3 JPT T S3 C1 A with ultrasonic cleaning PH400G O EA B when suffix code of PH4 PF4 specified PH450G A E when suffix code of PH5 PF5 specified PUS400G NN NN L E which power supply rating should be same as the pH converter Power supply rating of non reagent type free available chlorine analyzer should be same as the pH converter Specify if needed instead of the standard stanchion made of carbon steel Available only when the suffix code FC4 PH4 or PH5 is specified Available when free available chlor
8. Manual washing starts by pressing key with TIMER displayed and then key with START displayed To stop manual washing press key with STOP displayed lt PLAT gt Manual washing Note The status previously selected appears first gt Set washing intervals ia ata ls gt Set washing time ald a gt Set relieving time F5 12 3e ai IM 12F5A1 01E lt 5 Key Operation and Display gt d lt AZ CAL gt Auto Zero Calibration mode The activated charcoal filter is used and auto calibration is performed To turn this function ON service code 09 Wash Auto Calibration switch is set to 1 The default setting is O for Wash For Auto Zero Calibration mode the calibration interval INT D unit days calibration setup time WT min unit minutes and stabilization settling time RT min unit minutes are set The optimum time settings depend on the sample and the measurement environment lt PLAT gt Note The previously selected status is displayed Note Note 2 When the calibration interval is more than ee Seen ye a one day the zero filter flushing functions to cleanse the activated charcoal filter and y help prevent poisoning of the filter automatically TIMER OFF wash the filter with zero water once a day Set calibration interval Note 2 Set calibration setup time ENT WT min ENT RT min ENT Set stabilization setting time F5
9. and fix clamp 18 Mount brush If motor mounting plate was loosened in 16 adjust brush to split ring contact pressure to optimum value see Sec 8 2 1 This completes the replacement procedure Check that when power is applied to the FC400G the drive shaft drive belt and driven shaft rotate smoothly Confirm that there are no abnormal sounds like vibration or discontinuous noises IM 12F5A1 01E lt 8 Maintenance gt 8 9 8 2 4 Check Maintenance Replacement of Motor and Gear Head Procedure for Checking and Maintenance At zero calibration time operate the indicator electrode and check the following once in three months recommended e Check there s no irregularity in rotation speed of drive shaft If there s any irregularity loose the load on the shaft by loosening the screws which fix the driven shaft pulley and recheck If there is still irregularity replace motor and gear head If the irregularity doesn t reappear check the driven shaft assembly e Abnormal sound from gear head motor If there s any abnormal sound check the motor gear head In principle this should be done by Yokogawa Also approximately once in six months check the following items as well e Motor rated torque and drive torque In lt CELL gt mode when motor is turned ON OFF after the ON command it should quickly reach speed Confirm that the difference in speed of rotation between its normal status and when load is
10. 0 min at factory shipment Note Contact output status during washing is as shown below Output hold OFF ON OFF ON I I I l l l l I I OFF ON I OFF ON OFF 4 Contact output for l i 1 1 washing l l I I l 1 T1 Washing interval i I i 1 T2 Washing time Contact output for te T2 gt lt T3 gt la T2 gt K T3 gt T3 Releasing time Wash Auto zero l l i calibration 1 l T1 I lt lt seg F6 te ai 1 WASHICAL lamp blinks 5 2 Display Content on the Display Unit and W1 W2 of Figure 3 4 are operated Auto zero calibration lt AZ CAL gt Mode refer to Sec 7 2 3 e Auto zero calibration timer ON OFF setting Select T OFF if you don t want to use this timer otherwise select T ON e Auto zero calibration interval setting effective when T ON Set Auto zero calibration interval using INT D to between 0 1 and 99 9 days 10 0 is the shipping time default setting e Calibration setup time setting effective when T ON Set Calibration setup time using WT min to between 1 and 100 minutes 10 is the shipping time default setting e Stabilization settling setup time setting effective when T ON Set Stabilization settling setup time using RT min to between 1 and 100 minutes 10 is the shipping time default setting Optimum values for these time settings depend on sample and measurement environment When setting auto zero calibration parameters zero filter flushing function will be activated by s
11. 2 Cleaning the Ceramic Beads and Measuring Tank ceeeeee 8 3 8 1 3 CalibratlOn iriser asana aaa a aasid aaa adria 8 3 8 1 4 Replacement of Activated Charcoal Filter cccceeeeeeeeeeeteeeees 8 4 8 2 Checking the Electrode Mechanism Block and Replacing Damaged Parts8 4 8 2 1 Inspecting the Brush and Slip Ring ececeeeeeeeeeeeeeteeetteeeeeeenee 8 5 8 2 2 Check Maintenance Replacement of Drive Belt 00 8 6 8 2 3 Check Maintenance Replacement of Driven Shaft Assembly 8 7 8 2 4 Check Maintenance Replacement of Motor and Gear Head 8 9 9 TROUBLESHOOTING sscssisicsscevsccesevdecnenstacnssuadvacwoncretdcnsunessceemwrmuoerdsriunetaesss 9 1 9 1 When lt failure gt is Indicated csccecceceeeeseeseeeeeeneesseeeneneeneeseeeeeenteneeseeeneenets 9 1 9 1 1 Indication of Error Message or Error Code ecceecceeceeeeeeeeeereeneees 9 1 9 1 2 Remedies When Errors OCCUIS ccscceeeeeeeceeeeeeeseaeeteneeeeneeetees 9 1 9 2 For the Case Where No Error Indication AppearS ssecsesesseeeneeees 9 4 10 SPARE PARTS AND CONSUMABLEG ccsscssseesseeesseeeesseeeeeees 10 1 10 1 Spare Parts and Consumables List e csscsssseeceeeeeeeeseeeentesseeeeeeeeneeees 10 1 10 2 Spare ot e Oe 10 1 10 2 1 Polishing Powder KQ088PE ce ceceeceeseeeeeeeeeseeeeeeeeeeeeeeeeatens 10 1 10 2 2 Ceramic Beads K93322P xi cicsciedesecteactveevvidevtsteaetea
12. 3 Contact Output Cables siia a a 3 5 4 PARTS NAMES AND OPERATIONS cseeeeceseesesseneeeseeeeseneeeneneeeeees 4 1 41 Parts Names and Functions ccsscecssesssseeeeeseeseeseeeneeneseeseeeneneeseeeenenenaes 4 1 4 2 Operation Modes and Codes ssscscceccsessssseeeeseesseseeeeeeneesseeeneneeneeseeeeeeneneas 4 3 4 2 1 Modes In Operation levelere 4 3 4 2 2 Modes m Seting leveliss teic devia ona a detente 4 4 4 2 3 Modes in Service level ccccccececeeeeeeeeeeeeeeeeeeeneeeseeeeseaeeseueeseneeenans 4 4 IM 12F5A1 01E vi IM 12F5A1 01E lt CONTENTS gt NAMES OF COMPONENTS ep scaisciicisnscnastanceisncacetacinnannateandnaaseieatanieteneananie 5 1 5 1 Operation Key sisuna ceseatecettvethinadeateuencientiuareslenanduetivetdendeuansueten 5 1 5 2 Display Content on the Display Uniit s cescsssseeeeseeseeseeseeeseeseesseeeeneenees 5 2 5 3 Basic Key Operation aeacia cincciccsesiescccecctcestevieenceeecssrccesteeecvescsncsteettreirestenesnrtes 5 3 5 3 1 Key Operation When Indication BLINKS 5 3 5 3 2 Key Operation When A J ENT Indication Blinks 5 3 5 3 3 Mode Selection in the Operation Level cccccccceeeeeeeeeeeseeetees 5 5 5 3 4 Transfer to the Setting Level oo eeeeeeeeeeeeeeeeeeeneesneeeieeeiteeireeiteeas 5 5 5 3 5 Transfer to the Service Level vis cccccesccchivenscevavenccdhicevecevisewedvicevnaticerele 5 6 5 4 Mode Selecting Procedure for Each Level and Mode Conient
13. 4 2 3a ai e lt PLAT gt Plateau Mode Press the key to enter the setting level and press the key to select lt PLAT gt Press the key with MEAS displayed When the plateau characteristic collection performs enter key again In the plateau characteristic collection function MEAS setting initial applied voltage step applied voltage and step count and then selecting START causes mg l or ppm indication to blink displaying the applied voltage When the diffusion current value stabilizes the applied voltage and diffusion current values are stored in the memory to apply the next step voltage A step not needed can be aborted using the key This erases data in that step appears when such data is read and the operation moves to the next step When the voltage has been applied to all steps READ appears The data readout function READ displays in turn the data acquired previously each time the key is pressed IM 12F5A1 01E lt 5 Key Operation and Display gt 5 1 5 gt NO lt SERVC gt PLAT ves NO YES h MEAS NO READ YEs DA 0 O28 booo bees 5 initial appolied INI V ae i Display all steps in turn I Set step applied voltage A R 0 gt Set step count STP NO Diffusion current value A applied voltage value Measure all steps F5 12 4e eps f lt SERVC gt Service Level Enter the key at SERVC displayed COD
14. 9 10 0 100 200 300 400 500 pH Conductivity uS cm Figure 2 1 Sensitivity characteristics of Figure 2 2 Sensitivity characteristics of diffusion diffusion current by pH value current by conductivity Note If conductivity exceeds 300 uS cm default value of applied voltage should be changed Electrodes Indicator electrode Counter electrode Electrode Cleaning Converter Functions Display functions Diagnostic function Indicator electrode The combined chlorine insensitive version uses a gold alloy indicator electrode Silver chloride electrode with Pt 1000 RTD installed Ceramic bead cleaning The combined insensitive version uses glass beads Concentration sample temperature applied voltage diffusion current output signal zero point slope error display interactive message and key operation request display Excessive diffusion current value measured temperature error applied voltage error converter error temperature compensation range over zero point error slope abnormality and response error Functions settable executable during operation level Zero and span calibration selection of message area display content hold ON OFF selection cell motor ON OFF selection Functions settable executable in setting level Output range setting hold parameter setting wash auto calibration parameter setting plateau characteristic measurement Service level code entry Functions settable executable
15. Operation gt Figure 6 5 shows the relationship between the initial applied voltage step applied voltage and step count Plateau characteristic example Setting example Initial applied voltage OV 5 Step applied voltage 0 1 V Diffusion Step count 8 current 4 UA Relevant to the initial value 0 0 5 1 0 Applied voltage V StepO Step1 Step2 Step3 Step4 Step5 Step6 Step7 Steps y Initial Step applied applied gt voltage voltage Note Applied voltage changes towards the negative side Diffusion current sample count is step count 1 F6 2e ai Figure 6 5 Example of Plateau Characteristic Collection e Selection of plateau characteristic collection data readout To collect plateau characteristic data select message MEAS and press the key Pressing the key with MEAS displayed causes the FC400G to enter READ Pressing the key again calls up the previously collected data in turn Setting Initial Applied voltage when MEAS is selected Set initial applied voltage INI V in the range of 1 00 to 1 00 V This parameter is set to 1 00 V at factory shipment Setting Step Applied voltage when MEAS is selected Set step applied voltage STP V in the range of 1 00 to 1 00 V This parameter is set to 0 20 V at factory shipment Setting Step count when MEAS is selected Set step count STP NO in the range of 1 to 20 steps This parameter is set to step 10 at factory shipme
16. Part for electrode mechanism 1 3 years Gear Head 200 V 220 V K9334VA Part for electrode mechanism 1 3 years Activated Charcoal Filter L9862AY For zero calibration 1 Yearly Replacement intervals vary depending on the application 1 At the time of damage 2 Fuse may be used more than one year we recommend periodical replace for planning maintenance IM 12F5A1 01E lt 6 Operation gt 6 1 6 6 1 6 1 1 6 1 2 OPERATION Preparation for Operation Inspecting Piping and Cable Installation Condition Confirm that the piping and wiring to the FC400G free available chlorine analyzer have been correctly installed For details of wiring refer to Sec 3 3 Filling with Ceramic Beads for Electrode Polishing Surface contamination of the indicator electrode results in measured value error To avoid contamination caused error the electrode surface is continuously polished by ceramic beads during FC400G operation Ceramic beads are not filled into the beads case at factory shipment Thus pour the ceramic beads provided in the accessory box into the beads case as follows before starting the FC400G The combined chlorine insensitive version uses glass beads Before operation ceramic beads are filled into the beads case of the detector How to fill the ceramic beads Unscrew two fixing screws at the bottom of the electrode mechanism block see Figure 6 3 to remove the measuring tank Th
17. and may possibly cause electrode contamination Clean the ceramic beads periodically Also simultaneously clean the measuring tank Clean them as follows 1 Turn OFF the power switch provided in the power line or remove the fuse provided in the converter to stop the free available chlorine analyzer Note Be alert to the fact that even if the fuse is removed live voltage remains on one side of the AC power line 2 Unscrew two screws fixing the electrode mechanism block to remove the mechanism block from the measuring tank 3 Remove the beads case containing the ceramic beads from the measuring tank In so doing remove the beads case cover together with the beads case 4 Clean the measuring tank Using a brush and neutral detergent sufficiently remove contamination from the measuring tank For adhesion of manganese or iron use diluted hydrochloric acid Finally wash off the detergent from the measuring tank using water Note Never attempt to use organic solvent for cleaning 5 Pour the ceramic beads into another container remove contamination using diluted hydro chlorine acid and sufficiently wash the beads with water 6 Clean beads case and beads case cover For the beads case and beads case cover clean both in the same manner as measuring tank cleaning in item 4 Note The beads case cover may turn whitish during prolonged use however it causes no functional problem 7 Set the beads case cover onto the beads
18. at the bottom is the cause Stop the rotation and check see six monthly check below Manually turn the driven shaft and confirm that it s as smooth as usual If there is any clatter if drive belt has come off or shaft does not rotate easily or a rubbing noise is evident promptly replace the driven shaft assembly Replacing the driven shaft assembly If the bearing has become bad replace the driven shaft assembly In principle this should be done by Yokogawa s service facility If the user wishes to replace it the procedure is as follows Items 1 to 9 relate to disassembly and items from 10 onwards relate to reassembly 1 2 8 9 Shut off the power fed to the FC400G then place the electrode mechanism block in the maintenance position then remove the cover from the electrode part Remove indicator electrode and counter electrode To remove the indicator electrode inset the supplied Allen wrench into the socket of the driven shaft to stop it from rotating Disconnect the three wires connected to the counter electrode next loosen and remove the clamp holding the electrode in its holder Remove the brushes Remove the two screws holding the brushes one also holds wiring terminal Remove the bracket which holds the brush by loosening the 2 screws which holds the bracket and remove the rock screw at side of contact pressure adjusting screw Remove the drive belt Individually remove from the pul
19. calibration mode zero filter flushing is cancelled 3 During zero filter flushing only key and key are enabled pressing either of these keys aborts zero filter flushing and immediately the analog output hold is released lt HOLD gt and lt FLUSH gt go OFF and the lt MAINT gt contact output goes OFF 4 Counting continues regardless of timer operation mode 5 In lt MAINT gt mode if the zero filter flushing counter reaches its count up setting then zero filter flushing is cancelled not triggered that time the timer is reset and counting restarts IM 12F5A1 01E 7 6 7 3 lt 7 Calibration gt Span Calibration A NOTE 7 3 1 Before performing span calibration confirm that the electrode does not remain exposed to the air as after zero calibration and the electrode rotates normally in the measuring tank When both the zero point and span are calibrated calibrate first the zero point and then the span There are two span calibration methods One is a sampling method in which the reading of the FC400G is adjusted to the value obtained by manual analysis The other is a standard solution method in which the reading is adjusted to the concentration value of calibration standard solution free chlorine concentration of approx 80 of the output range Use of the sampling method is suitable to calibrate the FC400G more correctly for example when always measuring near zero low concentrations of free chlo
20. carton near the place of installation Installation Site Install the FC400G free available chlorine analyzer at a location that 1 is free from rain water such as an indoor location or in a cabinet 2 has low vibration 3 4 5 has low temperature variation and where the temperature is maintained at or as near to room temperature as possible has low corrosive gas 2 3 4 is low humidity 5 6 allows sufficient maintenance space with easy maintenance access and 7 allows drainage Mounting The FC400G Non Reagent type Free Available Chlorine Analyzer mounts vertically or horizontally on a sturdy pipe JIS 50A using U bolts see diagram To mount it on a plate or wall drill M8 size holes separated by 70 mm for the U bolt holes Where necessary use a sampling system to regulate the pressure and flow of the measurement liquid Normally the FC400G would be mounted in the sampling system in this case Figure 3 1 shows a combination of the FC400G with a special sampling system ST401G FC4 When using this refer to its instruction manual IM12A0V2 E regarding installation requirements
21. case and pour the cleaned ceramic beads into the beads case If the beads have obviously become smaller in size much smaller than a diameter of 1 7 to 2 3 mm replace them with new ones Ceramic beads are worn in long term use thereby reducing the ability of polishing indicator electrode The ceramic beads should be entirely replaced once every year For optimum polishing the new ceramic beads are normally filled up to the bottommost notch of the beads case when the indicator electrode is inserted The polishing ability cannot be recovered by replenishing the beads only by volume reduced by wear 8 Return the electrode mechanism block in place and firmly tighten the two fixing screws 9 Turn ON the power switch or return the fuse in place to restart operation Calibration After polishing the indicator electrode calibrate the zero point and span in the manner described in Chapter 7 It is recommended that calibration be conducted every month in the initial stage of FC400G operation to determine the degree of contamination on the indicator electrode This may be a guidance for determining appropriate maintenance intervals IM 12F5A1 01E lt 8 Maintenance gt 8 9 8 2 4 Check Maintenance Replacement of Motor and Gear Head Procedure for Checking and Maintenance At zero calibration time operate the indicator electrode and check the following once in three months recommended Check there s no irregularity
22. every two years is standard As a rule replacement should be made as a pair Procedures for adjusting the brush contact pressure and removing wear debris from the slip ring Wear debris generated from the sliding action of the slip ring and brush generated largely at the beginning may enter between the slip ring and the brush thereby temporarily increasing the contact resistance This may cause a drop in readings When this phenomenon occurs polish and clean the surface of the slip ring to prevent the generation of wear debris and the ingress of wear debris generated into a space between the slip ring and the brush and furthermore increase the contact pressure of the brush to the slip ring surface 1 Polishing and cleaning the surface of the slip ring With the FC400G being powered press sandpaper 2000 on the rotating slip ring Then press a cotton swab soaked in alcohol on the rotating slip ring to wipe off debris 2 Increasing the brush contact pressure Turn off power to the FC400G Loosen the lock screw next to the contact pressure adjusting screw and then the 2 fixing screws for the brush mounting bracket Turn the contact pressure adjusting screw in 1 2 turn Tighten the lock screws and bracket fixing screws Make sure that the brush does not come in contact with the pulleys and does not come off the slip ring Then turn on the power 10 2 7 Driven Shaft Assembly K9334JV The two bearings on the driven shaft assembly are to en
23. hand over the user s manuals to your end users so that they can keep the user s manuals on hand for convenient reference Please read the information thoroughly before using the product The purpose of these user s manuals is not to warrant that the product is well suited to any particular purpose but rather to describe the functional details of the product No part of the user s manuals may be transferred or reproduced without prior written consent from YOKOGAWA YOKOGAWA reserves the right to make improvements in the user s manuals and product at any time without notice or obligation If you have any questions or you find mistakes or omissions in the user s manuals please contact our sales representative or your local distributor m Warning and Disclaimer The product is provided on an as is basis YOKOGAWA shall have neither liability nor responsibility to any person or entity with respect to any direct or indirect loss or damage arising from using the product or any defect of the product that YOKOGAWA can not predict in advance Media No IM 12F5A1 01E CD Ath Edition Apr 2012 YK IM 12F5A1 01E All Rights Reserved Copyright 2003 Yokogawa Electric Corporation lt INTRODUCTION gt Notes on Hardware Appearance and Accessories Check the following when you receive the product e Appearance e Standard accessories Contact our sales representative or your local distributor if the product s coating
24. has come off it has been damaged or there is shortage of required accessories Model and Suffix Codes The name plate on the product contains the model and suffix codes Compare them with those in the general specification to make sure the product is the correct one If you have any questions contact our sales representative or your local distributor Before Measurement The FC400G Free Available Chlorine Analyzer is preset with defaults prior factory shipment Before measurement verify that these factory default settings meet the operating conditions and if neces sary reconfigure parameters For details of setting data refer to chapters 5 and 6 When user changes the operation parameter it is recommended to note down the changed data Symbol Marks Throughout this user s manual you will find several different types of symbols are used to identify different sections of text This section describes these icons warNING Identifies instructions that must be observed in order to avoid physical injury and electric shock or death of the operator A CAUTION Identifies instructions that must be observed in order to prevent the software or hardware from being damaged or the system from becoming faulty A IMPORTANT Indicates that operating the hardware or software in this manner may damage it or lead to system failure AN NOTE Identifies important information required to understand operations or functions IM
25. in rotation speed of drive shaft If there s any irregularity loose the load on the shaft by loosening the screws which fix the driven shaft pulley and recheck If there is still irregularity replace motor and gear head If the irregularity doesn t reappear check the driven shaft assembly Abnormal sound from gear head motor If there s any abnormal sound check the motor gear head In principle this should be done by Yokogawa Also approximately once in six months check the following items as well Motor rated torque and drive torque In lt CELL gt mode when motor is turned ON OFF after the ON command it should quickly reach speed Confirm that the difference in speed of rotation between its normal status and when load is reduced by loosening screws fixing pulley to driven shaft is not noticeable If operation is still not satisfactory replace motor and gear head Replacement procedure Replacement of motor and gear head should in principle be carried out by Yokogawa service If you want to do it yourself the procedure is as follows In principle replace motor and gear head at the same time as periodic replacement of other parts Replace complete motor assembly consisting of both motor and capacitor When replacing motor assembly and gear head first remove motor mounting plate from base There are no special cautions relating to removal of or reassembly of motor assembly and gear head however the par
26. in the lt MEASURE gt mode These indications will not disappear unless the cause is removed NOTE Slope error Err 5 generated when span calibration is performed using manual analysis except the amperometric titration AT method Initial electrode sensitivity set at the time of shipment is established based on the AT method When span calibration is performed based on a manual analysis method such as OT or DPD method other than the AT method a slope error END E5 Err 5 may occur due to the difference between the detecting sensitivity of the AT method and that of another method In that case initialize electrode sensitivity and perform span calibration If no error occurs during manual analysis other than the AT method there is no practical problem even when the initial sensitivity set at the time of shipment is not changed Note To initialize the electrode sensitivity set service code 08 to 1 for initialize electrode sensitivity before performing calibration refer to Sec 5 4 2 f IM 12F5A1 01E 8 8 1 lt 8 Maintenance gt 8 1 INSPECTION AND MAINTENANCE This chapter describes the inspection and maintenance required to maintain the FC400G operation in good condition Inspection and Maintenance Items and Implementation Cycle The table below shows the principal inspection and maintenance items and recommended maintenance intervals to maintain good operating condition Actual maintenance interva
27. it to stabilize 5 Perform zero calibration Check that the data displayed on the data display has stabilized then press the key While calibration is being performed a blinking mg l or ppm is displayed When calibration ends normally ZR END is displayed Note During calibration if an abnormality occurs then END E6 or END E7 are displayed Refer to Sec 7 4 for a description of how to fix the problem 6 Exiting Zero calibration Confirm that a normal ZR END rather than an error message then press the key Pressing the key switches the display to SPAN After stopping the indicator electrode revert the electrode to its position in the measuring tank After fixing the electrode mechanism block to the measuring tank restart electrode rotation Perform span calibration see Sec 7 3 after performing zero calibration Auto Zero Calibration using Chlorine free chlorine not included Water Auto Zero Calibration is performed using an activated charcoal filter Setup as follows 1 In Service Level code 09 Washing Auto zero calibration set 1 for Auto zero calibration The default is O for washing 2 Select AZ CAL for Auto zero calibration sequence in Setting Level After selecting Auto Zero Calibration timer ON T ON select Calibration Interval INT D Calibration Setup time WT min and Stabilization settling time RT min Default values are For Calibrat
28. of 2PKSERVICE code 10 see item f f in 5 4 2 SERVE einot air MODE YES NO Co To F5 4 2 1 ai QP Note If any code other than code 01 02 04 05 07 08 and 10 for example code 80 is inadvertently entered immediately press the CEE key to exit from the service level IM 12F5A1 01E lt 5 Key Operation and Display gt a lt OUTPU gt Output range setting mode Press the key to enter setting level and to select lt OUTPU gt Set concentration value corresponding to each output span Set span to at least 1 00 mg L or ppm When service code 05 Two line segment output is set ON then set 50 and 100 outputs Default for this parameter is OFF OUTPU YES lt SET HD gt ST 1 00 ae 50 0 1 Range 1 output 50 value setting applies only Two line segment output oi 0 0 aoe 100 0 1 Range 1 output 100 value setting Range 2 output 50 value setting applies only when Two line segment output is ON and remote range switching is ON 5 0 aes 50 0 2 ND 3 00 OS 100 0 2 Range 2 output 100 value setting When remote range switching is ON F5 12 1e ai b lt SET HD gt Hold Parameter Setting Mode Press the key to enter the setting level and press the key to select lt SET HD gt Pressing the key with HLD ON displayed causes the FC400G to enter calibration setting level and service level a
29. of Table 6 2 Setting Item List 10 Some revision of Figure 6 5 11 to 6 12 Some revision of 6 3 3 Setting in the Service level 1 to 8 2 Some revision of 8 1 1 Polishing the Indicator Electrode 4 Some revision of Figure 8 4 5 Some revision of Figure 8 5 6 Some revision of 8 2 2 Check Maintenance Replacement of Drive Belt 7 to 8 8 Some revision of 8 2 3 Check Maintenance Replacement of Driven Shaft Assembly 1 Some revision of 9 1 1 Indication of Error Message or Error Code 10 1 Some revision of 10 1 Spare Parts and Consumables List P 10 3 Some revision of 10 2 9 Motor assembly See CMPL 10 2 10 Gear head See CMPL CMPL 12F05A01 01E revised to 7th edition item 3 P N of page 3 changed Service code 03 description corrected U0 U0 0 0 0 00 70 0 0 0 0 00070 4 5 5 6 6 6 6 6 8 8 8 8 8 9 1 Mar 2011 3rd Edition Remake and all pages changed Feb 2003 2nd Edition Stanchion model changed Combined chlorine insensitive version option CC operation for auto zero calibration etc added All pages changed Jan 1993 1st Edition Newly published IM 12F5A1 01E E f you want to have more information about Yokogawa products you can visit Yokogawa s home page at the following web site Home page http www yokogawa com an IM 12F5A1 01E Manual Free Available Chlorine Analyzer Supplement Thank you for selecting
30. of the needle valve so that the sample water flows at the specified flow rate IM 12F5A1 01E 7 8 7 4 7 4 1 7 4 2 lt 7 Calibration gt 7 Press the key to end the calibration and switch the FC400G to the MEAS mode Press the key to switch the FC400G to the lt MEASURE gt or lt HOLD gt mode HOLD ON in the message display When HOLD ON is displayed press the key to select the lt MEASURE gt mode Remedies When Errors Occur in Zero or Span Calibration If Errors occur during Calibration If error occurs during Zero or span calibration the FC400G free available chlorine analyzer displays FAIL on the LCD and generates an error message as follows 1 During Zero Calibration END E6 Zero point error Err 6 END E7 Response error during the calibration Err 7 2 During Span Calibration END E5 Slope error Err 5 END E7 Response error during the calibration Err 7 Note If multiple errors occur the error with the highest priority appears Priority is Err 5 gt Err 6 gt Err 7 Remedies When an Error Occurs 1 Press the key to perform calibration again and confirm that the error does not occur again 2 Ifthe error occurs again refer to Sec 9 1 and remove the cause of the error and then perform calibration Note When an error occurs the concentration value based on the calibration data is displayed Also the error message and FALL remain displayed
31. plateau region It also generates signals for automatic temperature compensation of this diffusion current that varies with temperature The measuring tank is made of acrylic resin and contains ceramic beads in the part where a indicator electrode is inserted for polishing the electrode The electrode mechanism block incorporates an indicator electrode rotating electrode counter electrode Pt 1000 Q RTD built in silver chloride electrode and driving mechanism consisting of a synchronous motor that rotates the indicator electrode at a constant speed and a belt The converter s measuring circuit is housed together with an operation panel and external wiring connection terminal board in a closed aluminum casing This measuring circuit performs amplification and computation based on two signals from the detector to generate an output signal of 1 to 5 V DC or 4 to 20 mA DC corresponding to the output range lt Sampling System gt The FC400G sample inlet should have a pressure of 1 to 150 kPa a flow rate of 0 1 to 2 5 I min Sample meeting these conditions can be directly introduced to the measuring tank However measurement of sample not meeting such conditions requires installation of a sampling system to supply the required conditions YOKOGAWA s dedicated sampling system ST401G allows measurement of sample with a pressure of 100 to 750 kPa and flow rate of 0 1 to 10 l min IM 12F5A1 01E 1 2 lt 1 Overview gt 1 3 Measu
32. power switch Be careful not to turn on the power and cause an accident with the indicator electrode or belt used to rotate it when the cover is removed or the electrodes are parked in the maintenance position shown in Figure 6 3 Note When power is supplied the instrument enters measurement mode IM 12F5A1 01E lt 8 Maintenance gt When the electrode stops rotating the CELL lamp extinguishes Remove the electrode mechanism block from the measuring tank and set up the block as shown in Figure 8 2 The electrode mechanism block is fixed to the measuring tank using two screws at the lower part of the mechanism block Electrode mechanism block Electrode mechanism block cover Fixing screws 2 pes F6 2e ai Figure 8 1 Electrode Mechanism Figure 8 2 Under Maintenance 2 Block Fixing Screws Removing the Indicator Electrode Remove the electrode mechanism block cover from the detector Hold the gears so that the drive shaft does not turn and remove the ky indicator electrode The electrode is screwed into the drive shaft turn the electrode counterclockwise In so doing do not touch the brush Also exercise care so that you do not touch the electrode surface of the indicator electrode electrode surface F6 4 ai Figure 8 3 Appearance of the Indicator Electrode Polishing the Electrode Surface of the Indicator Electrode Spread the provided abrasive alumina onto dampened gauze and thoroughly clea
33. remains on one side of the AC power line 2 Unscrew two screws fixing the electrode mechanism block to remove the mechanism block from the measuring tank 3 Remove the beads case containing the ceramic beads from the measuring tank In so doing remove the beads case cover together with the beads case 4 Clean the measuring tank Using a brush and neutral detergent sufficiently remove contamination from the measuring tank For adhesion of manganese or iron use diluted hydrochloric acid Finally wash off the detergent from the measuring tank using water Note Never attempt to use organic solvent for cleaning 5 Pour the ceramic beads into another container remove contamination using diluted hydro chlorine acid and sufficiently wash the beads with water 6 Clean beads case and beads case cover For the beads case and beads case cover clean both in the same manner as measuring tank cleaning in item 4 Note The beads case cover may turn whitish during prolonged use however it causes no functional problem 7 Set the beads case cover onto the beads case and pour the cleaned ceramic beads into the beads case In this case if the amount of beads is below the notch in the beads case cover approx 40 mm from the bottom replenish the ceramic beads up to that level Note Ceramic beads undergo wear during long use reducing the cleaning effect it is recommended that the ceramic beads should be replaced every year reached a
34. span calibration see Sec 7 3 after performing zero calibration 7 2 2 7 2 3 lt 7 Calibration gt 7 3 Method of Zero Calibration using Chlorine free Water The method of performing Zero Calibration using Chlorine free Water is as follows Note that the electrode mechanism block should be secured to the measuring tank and the electrodes rotating 1 Prepare 2 3 liters of chlorine free water The chlorine free water should consist of pure water to which 10 ml of pH 7 buffer solution and 50 mg of NaCl has been added 2 Select lt CAL gt mode ZERO displayed in message display Note If Service Level code 08 is set to 1 for initialize electrode sensitivity then placing the unit in lt CAL gt mode results in NO CHNG or CHANGE being displayed In response see Sec 7 3 press the key and ZERO is displayed 3 Connect piping to supply chlorine free water to the FC400G Close the needle valve at the sample water inlet of the FC400G and remove the sample water piping from the joint to the measuring tank Release any sample water remaining in the measuring tank by opening the drain cock on the tank Use tubing and hardware to connect the chlorine free water tank to the sample water inlet Use a head difference or a pump to supply chlorine free water at a flow rate of at least 100 ml min 4 With the chlorine free water flowing at the specified flow rate watch the data display and wait for
35. stable immediately after cleaning the electrode this is the reason for leaving the instrument running for a while before calibrating it Refer to Chapter 7 for calibration requirements IM 12F5A1 01E lt 6 Operation gt 6 5 6 2 Normal Operation 6 2 1 Maintenance during Normal Operation Perform calibration regularly at the specified calibration interval Promptly fix any abnormality see Sec 9 1 After initial startup check how clean the indicator electrodes are one or two weeks before regular scheduled maintenance is due to determine whether the scheduled maintenance interval should be shortened 6 2 2 Shutting Down then Restarting Operation The data in the FC400G is retained even when power is disconnected If it is to be stopped for a long period then power should be disconnected If power will continue to be supplied it s recommended that the cell motor be stopped When restarting perform a checkup and maintenance see Chapter 8 IM 12F5A1 01E 6 6 6 3 lt 6 Operation gt Requirements for Setting Operation Data 6 3 1 Setting Items Table 6 1 shows different Operating and Setting items Table 6 2 shows Setting items in Service level Table 6 1 Setting Item List Set Values at Shipment and Their Setting Range 1 Setting Item at F ia Slem ent Selection and Setting Range Opera lt DISP gt Display Mode ee e Message area display content selection Temperature display Sample temperature d
36. the setting level If this error message appears the relevant data will not be updated Set correct value again so that the mg l or ppm value for 100 signal output exceeds the value for 50 signal output IM 12F5A1 01E 9 4 9 2 lt 9 Troubleshooting gt For the Case Where No Error Indication Appears There are cases where normal measurement is prevented such as in fluctuating set value even though no error is detected Table 9 2 shows such abnormalities possible causes and remedies Table 9 2 Abnormalities Their Possible Causes and Remedies Abnormalities Possible Causes Remedies Measured value is 1 Indicator electrode has stopped 1 Take steps as follows deviates significantly in the positive or negative direction or overshoot occurs performed correctly Span calibration was performed with electrode sensitivity initialization set to ON 1 in service code 08 CHANG Mode and using a calibration solution with a large difference in concentration from the input concentration value abnormal a Electrode drive belt does not turn a Sufficiently tighten the set screw b Cell motor does not run b Replace the motor with a new one 2 Indicator electrode has won out 2 Replace the electrode with a new one 3 Insufficient continuity between the 3 a Adjust the brush contact pressure and contact brush and slip ring at the remove wear debris from the sli
37. to the message CELL ON displayed to stop the rotation of the indicator electrode When the electrode stops rotating the CELL lamp extinguishes Remove the electrode mechanism block from the measuring tank and set up the block as shown in Figure 6 3 The electrode mechanism block is fixed to the measuring tank using two screws at the lower part of the mechanism block Electrode Electrode mechanism mechanism block block cover Fixing screws 2 pes F6 3e ai F6 2e ai Figure 6 2 Electrode Mechanism Figure 6 3 Under Maintenance Block Fixing Screws IM 12F5A1 01E lt 6 Operation gt 6 3 2 Removing the Indicator Electrode Remove the electrode mechanism block cover from the detector Hold the gears so that the drive shaft does not turn and remove the indicator electrode The electrode is screwed into the drive shaft turn the electrode counterclockwise In so doing do not touch the brush Also exercise care so that you do not touch the electrode surface of the indicator electrode electrode surface Q CS F6 4 ai Figure 6 4 Appearance of the Indicator Electrode 3 Polishing the Electrode Surface of the Indicator Electrode Spread the provided abrasive alumina onto dampened gauze and thoroughly clean the electrode surface using such gauze so that any contamination such as oil and grease is completely removed Then wash off any abrasives adhering to the electrode in clean running water After polishing and
38. voltage Start Slope x diffusion current value lt SERVC gt Procedure for Setting Applied voltage Compensation to OFF refer to 6 3 3 5 Code 07 Setting Applied voltage Compensation Parameters 1 Collect the plateau characteristic of the sample water refer to 5 4 2 e lt PLAT gt Plateau Mode and determine the applied voltage value 2 Enter the value of 1 in Applied voltage compensation parameter start and press the key 3 Set Applied voltage parameter compensation slope to 0 00V yA and press the CENT key 08 CHANG 0 a CHANG Set for normal use Set for electrode sensitivity initialization Note Electrode sensitivity initialization is used at startup and for the calibration immediately after the replacement of the indicator electrode Other than that set Normal use Please note that calibration for the electrode sensitivity initialization is performed unconditionally 1 1 Any value is written without determining whether or not it is a normal value If an incorrect calibration is performed the measurement values after the calibration may be incorrect 09 WAICA 0 Wash default 1 Auto zero calibration 10 RRNGE 0 0 Remote range switching OFF default as 1 Remote range switching ON R RNGE F5 12 7e eps IM 12F5A1 01E 6 6 1 6 1 1 lt 6 Operation gt 6 1 OPERATION Preparation for Operation Inspecting Piping and
39. you attempt to measure free available chlorine and the test solution contains combined chlorine there s an error which depends on the concentration of the combined chlorine To reduce the error in this sort of situation we recommend that you use the combined chlorine insensitive version of the Model FC400G that has been developed for this purpose Compared with the standard Model FC400G the electrodes the beads and the applied voltage are different but the unit is otherwise the same as the standard Model FC400G as regards measurement principles installation specifications and performance Figure 1 1 shows the appearance of the FC400G free available chlorine analyzer F1 1e ai Figure 1 1 FC400G Free Available Chlorine Analyzer IM 12F5A1 01E 1 2 lt 1 Overview gt 1 1 Configuration of the Free Available Chlorine Analyzer The FC400G free available chlorine analyzer is broadly divided into a free available chlorine analyzer main body FC400G and a sampling system The main body consists of a detector and converter and the sampling system consists of sample water piping and a needle valve lt Free Available Chlorine Analyzer Main Body gt The detector consists of a measuring tank and electrode mechanism block The detector electrolytically reduces free available chlorine in the sample water supplied to the measuring tank to obtain a diffusion current in the
40. 0 to 3 mg l Default ranges at shipping time are Range 1 0 to 2 mg l Range 2 0 to 3 mg l 4 to 20mA DC load resistance 550Q or less or 1 to 5V DC output resistance 3000 or less isolated 2 points Dry contact Excessive diffusion current value measured temperature error applied voltage error converter error and temperature compensation range over Any modes other than measurement MEAS mode Contact capacity 250 V AC max 1 Amax 125 VA max resistance load 220 V DC max 1 Amax 60 W max resistance load Main unit power OFF Main unit power ON During non operation In operation Event of Error Open Closed Open Maintenance Closed Open Closed Contact Input Sample Conditions Temperature pH Flow Rate Pressure Conductivity Remote range switching Switching between 2 preset ranges range 1 and range 2 0 V DC or contact open Range 1 5 V DC input impedance 250 KQ Range 2 0 to 50 C Temperature compensation range 0 to 40 C 6 5 to 7 5 see Figure 2 1 0 1 to 2 5 l min 1 to 150 kPa 100 to 750 kPa for the case where dedicated sampling system ST401G is provided 100 to 300 uS cm see Figure 2 2 SS Suspended Solid 10 mg l or less IM 12F5A1 01E 2 2 lt 2 Specifications gt 1 0 Ao a er PEE ssi B g pH6 5 pH7 5 0 8L T 2 oO ie FC400G a Operating range ae E 0 6 3 Li 0 44 0 0 3 3 4 5 6 T 8
41. 1 FC400G Free Available Chlorine Analyzer Non Reagent Type 2 1 2 1 2 Dedicated Sampling System for Non Reagent Type Free Available Chlorine AnalyZer ecccecceceeeeeteteeeteeeeeeeeneeeeeeaes 2 3 2 2 Characteristics iseseisana iaiaaeaia aaa 2 3 2 3 Model and Codes sscescsstsseeeeseeseeseneenenaeeesenesnenaeseeseeeneenaeseeseeeneeneeseeesnenenaes 2 4 2 3 1 Free Available Chlorine Analyzer Non Reagent Type eee 2 4 2 3 2 Sampling System eee eeeceeee tent eeneeeeeeeeeeeeeeeeeeeeeeaeeeeeeeeeeeetesas 2 4 2 3 3 Spale Pants aoan E E EAA EAEEREN 2 5 2 4 DIMonS Oh fees cto eras starch donaa aN 2 6 3 INSTALLATION PIPING AND WIRING s ccsssecssseessseeseseeeessneeenes 3 1 3 1 Instalati N i sini esac icoeccteesets cencectectencvenceeceenestncesendeetcsuecteeuseseetesnertenseredeecasuavenescct 3 1 3 1 1 installation Site is cee ces chee sete thareite aea a aa E 3 1 3 1 2 MOUNTING e eit enti abn aden ahve at 3 1 3 2 PUP UING ecsecnsecsseciseccsecseccneccavcuwecusveuteccewcuwecuuvcctecuavcuwecus EEEE 3 2 3 2 1 For Use without a Sampling SySteM eccecceeeeeteeeeeeteeeeeeeeeeeeeees 3 2 3 2 2 For Use with Dedicated Sampling System ccceceeeeeteeteeteeeees 3 3 3 3 WVU Goss 2s asses tccaths lata ees cca ahaa aa aaa a 3 4 3 3 1 Power Cable and Grounding Wire ccecceeceeceeceeeeeeeeeeeteeeeeeneeenes 3 5 3 3 2 Analog Output Signal Cable eececeeeeeereeeeeeeeeneeeneesneetieesneeeeee 3 5 3 3
42. 12F5A1 01E lt INTRODUCTION gt iii After sales Warranty E Do not modify the product E During the warranty period for repair under warranty carry or send the prod uct to the local sales representative or service office Yokogawa will replace or repair any damaged parts and return the product to you Before returning a product for repair under warranty provide us with the model name and serial number and a description of the problem Any diagrams or data explaining the problem would also be appreciated If we replace the product with a new one we won t provide you with a repair report Yokogawa warrants the product for the period stated in the pre purchase quotation Yokogawa shall conduct defined warranty service based on its standard When the customer site is located outside of the service area a fee for dispatching the maintenance engineer will be charged to the customer In the following cases customer will be charged repair fee regardless of war ranty period e Failure of components which are out of scope of warranty stated in instruction manual e Failure caused by usage of software hardware or auxiliary equipment which Yokogawa Electric did not supply e Failure due to improper or insufficient maintenance by user e Failure due to modification misuse or outside of specifications operation which Yokogawa does not authorize e Failure due to power supply voltage frequency being outside specifications or ab
43. 400G also generates fail contact output fail LED lights e Errors occurring during Maintenance If error occurs during maintenance during zero and or span calibration or during plateau characteristic collection the LCD displays an error message Err and to inform the operator of error signal occurrence However no fail contact output is generated and output signal overshooting does not function e Error occurring during Data Setting If data set during data setting is incorrect an error message NOTE appears for approx 2 sec to inform the operator of incorrect data setting In this case set data does not update the previous set correct data again Table 9 1 Error Message List Error No Error Content Classification on Difusion Gume nt VAIS exceeded Occurs during measurement or maintenance Err 2 Sample temperature error 9 i Err 3 Reserved error code presently not used Err 4 Applied voltage error Occurs during measurement or maintenance Err 5 Slope error Err 6 Zero point error Occurs during maintenance however only Err 7 Response error during zero or span during zero or span calibration calibration Temperature compensation range F Err 8 Note 1 exeoeded Occurs during measurement or maintenance Err 9 Reserved error code presently not used Err 10 Converter failure Occurs during measurement or maintenance NOTE 01 Input data setting range exceeded NOTE 02 Input data setting error O
44. A lt Service level gt Enter service code No Ko a5 SERVICE 2500C XOUTPU xC ODE JA OU TT ened G gt HOLD Pee EEE A F HOL DON JE In hold status Note 1 WASH may be displayed as AZ CAL depending on setting Corresponds to mode code in Sec 4 2 3 Service Mode 09 WA CA Washing Auto zero Calibration selection For the description of lt OUTPU gt see item a in 5 4 2 Set hold parameter SETHOLD xSETHI NO MODE YES p For the description of i lt SET HD gt see item b in 5 4 2 MODE YES C NO i For the description of lt WASH gt see f item c in 5 4 2 aT O O m Specify a setting item code number 01 For the description of code 01 see item f in 5 4 2 For the description of code 02 see item f in 5 4 2 For the description of code 04 see item f in 5 4 2 For the description of code 05 see item f in 5 4 2 Enter the plateau mode 07 ar ENT For the description of C code 07 see item f a PLATEAU in 5 4 2 PLAT JE Mane 08 Ja ENT YES _NO For the description of code 08 see item f EEEE AEE T in 5 4 2 For the description of i 09 tog i MODE r eee ne C For the description of aes item d in 5 4 2 code 09 see item f Cae cn 7t apart ye ata e in 5 4 2 Enter the servise level MODE ae ee C For the description
45. CTS display of converter panel Filling Zero Water and Test Operation For auto zero calibration to proceed smoothly you need to flow zero water chlorine free water through the zero filter case before starting then attach zero filter and operate without turning on auto calibration After replacing the filter or when the normal calibration interval has been exceeded you needs to run the instrument in offline mode for a while to allow conditions to stabilize before turning on the Auto Zero Calibration functions e Close BV2 and open BV3 ball valve e Be careful that water does not leak from activated charcoal filter F1 or piping and that there are no bubbles is pipeline e After 20 min operation like this confirm that residual chlorine reading is near zero Set auto zero interval warm up time and settling time according to the environment e Close BV3 and BV2 ball valve Setting Operation Parameters When the FC400G Free Available Chlorine Analyzer arrives at your site it will operate based on the initial data set at the time of shipment Set the appropriate parameters to suit your operation conditions Refer to Sec 6 3 for the types and operations of setting parameters Key operations for displaying the setting mode items and setting data are described in Chapter 5 Calibration Operate the FC400G for at least one hour under normal operating conditions before calibrating Note The electrode characteristics are not
46. Cable Installation Condition Confirm that the piping and wiring to the FC400G free available chlorine analyzer have been correctly installed For details of wiring refer to Sec 3 3 6 1 2 Filling with Ceramic Beads for Electrode Polishing Surface contamination of the indicator electrode results in measured value error To avoid contamination caused error the electrode surface is continuously polished by ceramic beads during FC400G operation Ceramic beads are not filled into the bead case at factory shipment Thus pour the ceramic beads provided in the accessory box into the bead case as follows before starting the FC400G The combined chlorine insensitive version uses glass beads Before operation ceramic beads are filled into the beads case of the detector How to fill the ceramic beads Unscrew two fixing screws at the bottom of the electrode mechanism block see Figure 6 3 to remove the measuring tank The ceramic beads are normally filled up to the bottommost notch of the beads case when the indicator electrode is inserted In maintenance position Electrode mechanism block Counter electrode reference electrode The bottommost notch of the beads case Indicator electrode Fixing screws rotating electrode 2 pcs es Beads case Ceramic beads Beads case cover F6 1e ai Figure 6 1 Measuring Tank Parts and Beads Case IM 12F5A1 01E 6 2 lt 6 Operation gt 6 1 3 Supplying Sample Water
47. E appears and enter the service level Enter codes 01 02 04 05 07 08 and 10 needed for setting various parameters in the service level Note Never attempt to enter a code other than codes 01 02 04 05 07 08 and 10 If inadvertent entry is made immediately press the key Entry of any code other than 01 02 04 05 07 08 and 10 may disable normal FC400G operation 01 TEMP q F F5 12 5e1 ai IM 12F5A1 01E 5 16 lt 5 Key Operation and Display gt 02 FAIL Temperature compensation range exceeded fail OFF Temperature compensation range exceeded fail ON Initial setting may apply This causes effect whether it is set to either 0 or 1 03 BURN Not used do not change the setting F5 12 5e ai Setting of determination parameter AT SEC for calibration Setting of determination parameter APPM for calibration ENT Setting of determination parameter CT min for calibration Note These parameters are also used in checking la stability during plateau measurement lt SERVC gt 05 NONLN c TEPEE Linear output fessa Two line segment output F5 12 6e eps IM 12F5A1 01E lt 5 Key Operation and Display gt 5 17 06 Reserved Code currently not used 07 DRVV Set applied voltage compensation parameter Start Set applied voltage compensation parameter Slope call Note Applied voltage is controlled based on the following equation Applied
48. Figure 6 8 This requires applied voltage compensation be made as expressed by the following equation Applied voltage DRV V V uA x diffusion current value Optimum applied voltage N Current V A Applied voltage gt DRV V F6 8e ai Figure 6 8 Plateau Characteristic of the Free Available Chlorine Analyzer e Setting DRV V Start Applied voltage Value Set start applied voltage value DRV V in the range of 1 50 to 1 50 V This parameter is set to 0 10 V at factory shipment Set to 0 1 V in to decrease influence of combined chlorine insensitive version option Setting V A Slope Value Set the slope value or applied voltage change V yA per 1 WA in the range of 0 10 to 0 00 V A This parameter is set to 0 02 V pA at factory shipment Set to 0 01V UA in to decrease influence of combined chlorine insensitive version option 6 Code08 Selecting Electrode Sensitivity Initialization ON OFF CHANG Mode Set this parameter to 1 only if you wish to rewrite the slope SL displayed in the message area selectable in the operation level lt DISP gt mode to 1 00 e g for electrode replacement Generally set this parameter to 0 This allows the sensitivity relative to the sensitivity reached when the parameter is rewritten to 1 00 to be checked using SL This parameter is set to 0 initialization OFF at factory shipment 7 Code09 Washing Auto ze
49. X a y NO m 4 y tt tt PVC tray Drain VP40 l Figure 3 3 Piping Diagram of ST401G Sampling System IM 12F5A1 01E 3 4 lt 3 Installation Piping and Wiring gt 3 3 Wiring The types of wiring required by the FC400G free available chlorine analyzer non reagent type are as shown below All are connected to wiring terminals M3 screw in the converter 1 Power cable and grounding wire 2 Analog output signal cable 3 Contact output lt MAINT gt lt FAIL gt cables when required FC400G Converter 3 Receiver Analog output signal cable For remote range switching ST Auto Zero Cal valve power ST Supplied with ST401G sampling system Ground To power To power supply F3 3 1e ai supply Note All are connected to wiring terminals M3 screw in the converter 1 Be sure to ground the case ground terminal M4 screw or if this is not possible then connect to G of power wiring Avoid two point ground Case is connected to signal ground inside converter 2 Use cable with 9 to12 mm OD 3 Use two core shielded cable with 9 12 mm OD To avoid two point ground connect shield to ground at one end only 4 Contact input to be applied the voltage Figure 3 4 External Wiring Diagram Ve Bom CR Wiring terminal board De Eem Fe C Output signal Spare Analog
50. _ User s EXA Fc Manual Model FC400G Free Available Chlorine Analyzer Non Reagent Type IM 12F5A1 01E vigilantplant YOKOGAWA IM 12F5A1 01E Yokogawa Electric Corporation ane lt INTRODUCTION gt i INTRODUCTION E Safety Protection and Modification of the Product In order to protect the system controlled by the product and the product itself and ensure safe operation observe the safety precautions described in this user s manual We assume no liability for safety if users fail to observe these instructions when operating the product If this instrument is used in a manner not specified in this user s manual the protection provided by this instrument may be impaired If any protection or safety circuit is required for the system controlled by the product or for the product itself prepare it separately Be sure to use the spare parts approved by Yokogawa Electric Corporation hereafter simply referred to as YOKOGAWA when replacing parts or consumables Modification of the product is strictly prohibited The following symbols are used in the product and user s manual to indicate that there are precautions for safety A CAUTION A CAUTION sign denotes a hazard It calls attention to procedure practice condition or the like which if not correctly performed or adhered to could result in damage to or destruction of part or all of the product E Notes on Handling User s Manuals Please
51. age output slope or Zero point 2 lt CAL gt Calibration Mode Press the key in measurement mode and enter the operation level Press the key in message indicator CAL to select the lt CAL gt mode lt DISP gt YES le lab in These indications appear only when electrode sensitivity initialization is set to ON in service code 08 Leas NO CHNG net CHANGE YES tsaga Note For calibration upon replacement of the indicator electrode select CHANGE and then conduct calibration This causes Slope is not rewritten to 1 00 If Slope is not rewritten select NO CHNG or set service code 08 to OFF Set a standard chlorine solution concentration value using the CS or CX key CAL END YES lt MEASURE gt or lt HOLD gt F5 8 ai At O pressing the key causes mg l or ppm indication to blink starting automatic zero calibration When the calibration ends ZR END appears At select a calibration solution concentration value using the CD or key Press the key This causes mg l or ppm indication to blink starting automatic span calibration When the calibration ends CAL END appears IM 12F5A1 01E lt 5 Key Operation and Display gt 5 9 3 lt DISP gt Message Display Selection Mode Press the key and select the lt DISP gt mode using the Q key Select the message display content using the Cxo gt key Temperature C F diffusion current uA applied volt
52. age V output slope SL or zero point ZR can be displayed lt HOLD gt Temperature display Diffusion current display Applied voltage display Output current Slope display Relative sensitivity with respect to initial electrode sensitivity set in service code 08 Zero point display calibration pA Diffusion current value in zero lt MEASURE gt F5 9e ai IM 12F5A1 01E 5 10 lt 5 Key Operation and Display gt 4 lt HOLD gt Hold ON OFF Mode Unless HLD ON is established in the setting level the FC400G cannot enter this mode Press the key and select the lt HOLD gt mode using the Ix key Select setting or canceling with HOLD ON displayed press the key to set the lt HOLD gt mode or the key to cancel it In the hold mode the LCD displays the HOLD indication Hold cancel YES Hold setting lt MEASURE gt F5 10 1e ai 5 lt CELL gt Cell Motor ON OFF Mode Press the key and select the lt CELL gt mode using the Cxo key Select ON or OFF with CELL ON displayed press the key to turn the motor ON or CroD key to turn it OFF Cell motor OFF YES Cell motor ON lt MEASURE gt F5 10 2e ai IM 12F5A1 01E lt 5 Key Operation and Display gt 5 11 5 4 2 Modes in the Setting Service Level and Selection of Their Setting Items C r M MEASURE D ANRI lt Setting level gt o Set output range D Xp OUTPUT L
53. aning combined chlorine insensitive 1 Yearly type indicator electrode 2 bags 1Q ty Polishing Powder Alumina K9088PE For polishing indicator electrode 1 Yearly Brush K9332JX Part for electrode mechanism block 1 2 years Slip Ring K9332JZ Part for electrode mechanism block 1 2 years Fuse A1111EF 2A 1 Yearly Driven Shaft Assembly K9334JV Part for electrode mechanism block 1 3 years O Ring Y9115XB_ Part for electrode mechanism block 1 3 years Drive Belt L9804UK Part for electrode mechanism block 1 3 years Motor Assembly 100 V K9334JY Part for electrode mechanism block 1 3 years Motor Assembly 110 V K9334VQ_ Part for electrode mechanism block 1 3 years Motor Assembly 200 V K9334VR_ Part for electrode mechanism block 1 3 years Motor Assembly 220 V K9334VS Part for electrode mechanism block 1 3 years Gear Head 100 V 110 V K9332JP Part for electrode mechanism block 1 3 years Gear Head 200 V 220 V K9334VA Part for electrode mechanism block 1 3 years Activated Charcoal Filter L9862AY For zero calibration 1 Yearly Used to replenish or replace the ceramic beads used for automatic cleaning of the indicator electrode when their amount diminishes below the specified level or their contamination can no longer be removed The amount of the beads for replenishment or replacement differs with the FC400G operating conditions Generally approx one to two bags of beads per year are required One bottle of ceramic beads i
54. as the following codes required to set various data IM 12F5A1 01E Code 01 TEMP Selects C or F 02 FAIL Selects temperature compensation range exceeding fail ON OFF 04 AT SEC Sets stability determination parameter AT APPM Sets stability determination parameter APPM CT min Sets stability determination parameter CT 05 NONLN Selects linear output or two line segment output 07 DRVV Sets applied voltage compensation parameter Start V pA Sets applied voltage compensation parameter Slope 08 CHANG Selects electrode sensitivity initialization ON OFF 09 WA CA Select Wash or Auto Zero calibration 10 R RNGE Turn ON OFF Remote Range Selection Press key to exit from service level Note If you accidentally enter codes other than 01 02 04 05 07 08 and 10 for example 80 immediately press the key to exit from service level lt 5 Key Operation and Display gt 5 1 5 NAMES OF COMPONENTS All keys on the FC400G free available chlorine analyzer non reagent type are available in an interactive manner This allows easy operation that can be accomplished in accordance with displayed message indicator and operation key indicator 5 1 Operation Keys MEASURE OUTPUT SET HOLD WASH CAL PLATEAU SERVICE YES NO MODE CONTACTS 5 O gt GD CDO oml OMAINT OWASH CAL i ENT OCELL Omma D CD YES NO D D Used to respond to a message by pressi
55. ases However in general it is recommended that the indicator electrode be polished every month For polishing procedure follow Sec 6 1 4 when the electrode is polished zero point and span must always be calibrated While the indicator electrode rotates at 600 rpm at 50 Hz the electrode is automatically polished with ceramic beads However this does not completely prevent adhesion of contamination contamination gradually accumulates on the electrode surface over time Therefore the electrode surface must be polished manually with polishing powder alumina to remove such contamination before the measurement error exceeds the allowance For the polishing procedure follow Sec 6 1 4 In particular polish the electrode surface as described when it has become corrugated or deformed from the original shape circle with a diameter of about 3 mm Note It is recommended to polish the indicator electrode every month Every two or three months may be sufficient in some cases the required polishing frequency differs with the quality of the sampling water After polishing the electrode surface conduct calibration with running in operation 1 Press the key on the converter to enter the operation level and press the key to select the lt CELL gt mode cell motor ON OFF Press the key with respect to the message CELL ON displayed to stop the rotation of the indicator electrode IM 12F5A1 01E 8 2 lt 8 Maintenance gt When t
56. awa the part no is K9044FX Be careful not to get this grease on the outer surface particularly the gold surface Apply a small quantity half a drop of grease to a small flat screwdriver about 3 mm wide blade and apply to three equidistant places around the tapped hole about 3 to 5 mm inside the tip Next screw the indicator electrode into this tapped threaded hole Next unscrew the electrode and check that no grease has been extruded to the outer surface If it has remove it with a cloth that has been wetted with alkaline soap solution AK NOTE If the conductive silicon grease gets on the electrode surface then measurement accuracy is likely to be affected Conductive silicon grease needs to be applied only once 10 2 4 Counter Electrode K9332MK The counter electrode does not wear like the indicator electrode it can be continuously used without replacement However recommended practice is to keep one spare always available in case of accidental breakage 10 2 5 Fuse A1111EF Yearly fuse replacement in the converter is recommended to avoid unexpected operation stoppage IM 12F5A1 01E lt 10 Spare Parts and Consumables gt 10 3 10 2 6 Brush K9332JX and Slip Ring K9332JZ A CAUTION Do not touch the brush except when replacement is performed As the brush in the electrode mechanism block is used in contact with the rotating slip ring both parts are worn over a long time Generally replacement
57. ay and perform span calibration Confirm that the obtained value has been entered correctly and press the key This causes IM 12F5A1 01E 7 3 2 Note lt 7 Calibration gt 7 7 the mg l or ppm indication to blink during calibration operation When the span calibration is completed normally CAL END appears If an error occurs during calibration operation END E5 or END E7 is displayed in the message When this message is displayed take countermeasures referring to Sec 7 4 Press the key to end the calibration and switch the FC400G to the MEAS mode Press the key to switch the FC400G to the lt MEASURE gt or lt HOLD gt mode HOLD ON in the message display When HOLD ON is displayed press the key to select the lt MEASURE gt mode Span Calibration Using the Standard Solution Method Note To prepare standard solution the following materials are required approx 2 to 3 liters of pure water approx 20 to 30 milliliters of pH7 buffer solution approx 100 to 150 mg of NaCl and commercially available sodium hypochlorite or NaClO the quantity of which is so much that a free chlorine concentration of approx 80 of the output range can be obtained by dilution Span calibration using the standard solution method is performed as follows Note Start Before performing span calibration confirm that the electrode does not remain open to the air as after zero calibration and the ele
58. ccurs during data setting NOTE 03 Input data setting error Note 1 This error Err 8 occurs only if exceeded temperature compensation range check is set to ON in service code 02 9 1 2 Remedies When Errors Occurs The possible cause of each error message is described in the following Take appropriate steps for each IM 12F5A1 01E 9 2 lt 9 Troubleshooting gt Err 1 Diffusion Current Value Exceeded Err 1 appears if the diffusion current during measurement exceeds the range of 9 00 to 26 00 HA Confirm if the applied voltage parameter value set in service code 07 is correct Also confirm that there is no grime or moisture adhesion resulting in insulation deterioration on the electrode cable connection Err 2 Sample Temperature Error Err 2 appears if sample temperature exceeds the range of 0 0 to 50 0 C Control sample temperature to be in the range of 0 0 to 50 0 C If the error indication fails to extinguish even when the sample temperature is in the range of 0 0 to 50 0 C RTD is possibly defective open circuited In this case replace the counter electrode Err 4 Applied Voltage Error Err 4 appears if the applied voltage output exceeds the range of 1 5 to 1 5 V Confirm if the applied voltage parameter value set in service code 07 is correct Err 5 Slope Error Err 5 appears if the initial sensitivity value value set to initialize electrode sensitivity in serv
59. cleaning confirm that contamination has been completely removed The clean electrode surface must be uniformly wetted Note Polish the electrode surface by following the instructions below when it has become corrugated or deformed from the original shape about 3 mm in diameter Polish the electrode surface with sandpaper about 600 until the surface becomes finely rounded Then polish it with sandpaper about 2000 and lastly with polishing powder alumina Make sure the electrode surface is clean and then install the indicator electrode Reduce the amount of ceramic beads if the electrode has deformed greatly The ceramic beads are normally filled up to the bottommost notch of the beads case when the indicator electrode is inserted 4 Installing the Indicator Electrode Hold the gears so that the drive shaft does not turn and sufficiently screw the electrode into the shaft During installation exercise care not to touch the electrode surface Note Polish the electrode surface again if you have touched it 5 Attach the electrode mechanism cover Then set the electrode mechanism block to the measuring tank in place and fasten it using the fixing screws Finally use the lt CELL gt mode in the operation level to rotate the electrode Supplying Power Before supplying power check that the fuse holder cap in the converter is not loose A power switch in the power line to the FC400G is used to turn power ON OFF the FC400G does n
60. ctrode rotates smoothly in the measuring tank span calibration at the point when zero calibration using the method described in Sec 7 2 1 or 7 2 2 is finished and SPAN is displayed in the message display Note 1 2 Notes 3 5 Note 6 When calibration is performed using the method in Sec 7 2 1 the FC400G is in the MEAS mode or lt HOLD gt mode and SPAN is not displayed Refer to 2 of Sec 5 4 1 and display SPAN in the lt CAL gt mode Press the key to enter the span calibration mode Free chlorine concentration is displayed in the data display Prepare standard solution First prepare a solution to dilute commercially available sodium hypochlorite solution Prepare a solution for dilution so that it consists of 10 milliliters of pH7 standard solution and 50 milliliters of NaCl per one liter of pure water Calibration requires 2 to 3 liters of dilution solution Prepare a standard solution by diluting the sodium hypochlorite solution using the dilution solution so that the free chlorine concentration is approx 80 of the output range e To prepare a standard solution sample water may be used instead of dilution solution To prepare a span calibration solution according to the official method dilute the sodium hypochlorite using tap water so that the free chlorine concentration is approx 80 of the output range Supply the standard solution to the detector When the zero point ha
61. d sample in comparison with the RC400G Residual Chlorine Analyzer that uses reagent Also note that if combined chlorine is present in sample FC400G performance is affected Figure 1 2 shows the measuring circuit principle of the FC400G free available chlorine analyzer The FC400G applies voltage compensated in accordance with the diffusion current value between the indicator and counter electrodes and measures the diffusion current flow between the electrodes Temperature compensation is accomplished using the CPU which performs calculation based on the temperature signals received from the temperature measuring circuit Amplifier Current voltage conversion circuit Voltage Current apply voltage 4 to 20 mA or ing Applied voltage output 1to5V circuit compensation circuit Tempe rature measur ing circuit Measuring tank F1 2e ai Indicator Electrode Counter Electrode Figure 1 2 Measuring Circuit Principle IM 12F5A1 01E lt 2 Specifications gt 2 1 2 SPECIFICATIONS 2 1 Standard Specifications 2 1 1 FC400G Free Available Chlorine Analyzer Non Reagent Type Measured Object Measuring System Display Method Measuring Range Output Range Output Signal Contact Output Event of Error Maintenance Free chlorine in tap water Polarographic method using rotating electrode Digital 3 1 2 digit LCD display 0 to3mg Can switch between arbitrary ranges each between 0 to 1 mg l and
62. d voltage compensation 0 10 V Note 1 1 50 to 1 50 V parameter Start DRV V Setting of applied voltage compensation 0 02 V pA Note 2 0 10 to 0 00 V A parameter Slope V A Code 08 CHANG Mode Selection of electrode sensitivity initialization OFF 0 OFF 0 ON 1 ON OFF Code 09 WA CA Mode Wash Auto Zero Calibration Wash 0 Note 3 Wash 0 Auto Zero Calibration 1 Code 10 R RNGE Mode Remote Range switching ON OFF selection OFF 0 Note 4 OFF 0 ON 1 Note 1 Set to 0 1V in to decrease influence of combined chlorine insensitive version Note 2 Set to 0 01V yA in to decrease influence of combined chlorine insensitive version Note 3 When ST401G AZC is specified initial value is Auto Zero Calibration 1 Note 4 When ST401G RR is specified initial value is ON 1 IM 12F5A1 01E 6 8 lt 6 Operation gt 6 3 2 Setting in the Setting Level Unscrew four screws in the front panel of the FC400G converter to remove the converter case cover Then press the key to select the setting level a c IM 12F5A1 01E Output range setting lt OUTPU gt Mode When straight line output is selected using SERVICE code 05 you need to set only the concentration value corresponding to output of 100 The setting range is 0 00 to 3 00 mg L but the span should be set to at least 1 00 mg L When remote range switching is turned ON using SERVICE code 10 then set the concentration va
63. desired mode push key MODE key CELL ON OFF Mode Cro Setting level 777777 7 kd OUTPU Mode Service level key Y SET HD Mode WASH AZ CAL Mode Note v PLAT Mode Y SERVC Mode T R A E ap im wc gene ayy eames Yeh sae ame E key key can be used for returning MEASURE mode as ESC key Note Change mode by code 09 The operation of the FC400G free available chlorine analyzer non reagent type is determined in the following three control levels 1 Operation lev 2 Setting level 3 Service level The operation level applies to daily inspection or maintenance Keystroke in this level can be el accomplished with the converter case cover installed The setting and service levels are used to select a function and set data Function selection and data setting are generally made once before starting operation Also inadvertent change of such selection or setting should be prevented operation keys used for the setting level or service level cannot be externally accessible To change such selection or setting remove the converter case cover Modes in Operation level The FC400G can enter or exit from the operation level using the key The operation level has the following modes 1 MEASURE 2 CAL 3 DISP 4 HOLD 5 CELL Allows mg l or ppm and auxiliary indications Calibrates zero point and span Allows selection of the m
64. during service level Switching of C F temperature compensation range over check ON OFF straight line two line segment output selection applied voltage setting and applied voltage compensation rate setting Main Wetted Part Materials Measuring tank Piping Color Painting Finish Ambient temperature IM 12F5A1 01E Acrylic resin Flexible PVC and hard PVC Munsell 0 6GY3 1 2 0 and Munsell 2 5Y8 4 1 2 Baked polyurethane resin coating 10 to 55 C 2 2 lt 2 Specifications gt 2 3 Ambient humidity 5 to 95 RH no dew condensation allowed Storage Temperature 30 to 70 C Installation Indoor Outdoor use separately requires rainproof measures Direct sunlight must be avoided Utility Power supply 100 V AC 10 50 60 Hz 110 VAC 10 50 60 Hz 200 V AC 10 50 60 Hz 220 V AC 10 50 60 Hz Power consumption Approx 15 VA Mounting 2B pipe mounting or wall mounting Weight Approx 6 kg Dedicated Sampling System for Non Reagent Type Free Available Chlorine Analyzer Function Used for application having high pressure and large flow rate Refer to GS 12A00V02 01E Characteristics display shows value relative to the upper limit of a range Repeatability 2 Linearity 5 Drift Zero drift 1 month Span drift 10 month Response time Approx 2 min 90 response time Temperature compensation error water temperature 3 Temperature compensation range 0 to 40 C Ambient t
65. e For combined chlorine insensitive type 23 24 25 26 27 28 29 30 31 32 33 4 Capacitor Part No Qty K9334JV K9334LN Y9500ET L9805BG K9332LQ K9334JW Y9115XB L9831HC L9831HE L9852CB K9332KQ Y9114XB K9332KR Y9110XB K9332KP L9831KL L9831KN K9332KZ K9332ZP K9332ZJ K9332KX K9332KL K9332MS Motor Assembly a ee er or Description Shaft Assembly Shaft Retainer ring E Bearing Holder Bearing O Ring Nut Sleeve Valve Nipple O Ring Cock Assembly O Ring Insert Nut Sleeve Beads Case Cover Beads For general type For combined chlorine insensitive type Beads Case Measuring Cell Bracket CMPL 12F05A01 01E REVISION INFORMATION Title Model FC400G Free Available Chlorine Analyzer Non Reagent Type Manual No IM 12F5A1 01E Apr 2012 4th Edition P 1 3 Some revision of Figure 1 2 P 2 2 Some revision of service level code function P 2 5 Some revision of Note 2 for PH8HF MS code and 2 3 3 Spare Parts 3 3 Some revision of Figure 3 3 4 Some revision of 4 2 3 Modes in Service level 11 Some revision of 5 4 2 Modes in Service level and Selection of Their Setting Items 15 to 5 17 Some revision of f lt SERVC gt Service level 1 Some revision of 6 1 2 Filling with Ceramic Beads for Electrode Polishing 3 Some revision of 6 1 4 Polishing the Indicator Electrode 7 Some revision
66. e 7 Available when free available chlorine analyzer is specified singly by suffix code FC4 An arrester is supplied automatically with this option 2 3 3 Spare Parts age Recommended Name Part No Description Q ty replacement interval Indicator Electrode Rotating electrode K9332MB Gold electrode 1 Yearly Indicator Electrode Rotating electrode K9334JP Gold alloy indicator electrode 1 Yearly Counter Electrode K9332MK Silver chloride electrode 1 1 For cleaning general type indicator elec Ceramic Beads K9332ZP trode 2 bags 1 Yearly Glass Beads K9332ZJ For cleaning combined chlorine insensitive 1 Yean type indicator electrode 2 bags 1Q ty y Polishing Powder Alumina K9088PE For polishing indicator electrode 1 Brush K9332JX Part for electrode mechanism 1 2 years Slip Ring K9332JZ Part for electrode mechanism 1 2 years Fuse A1111EF 2A 1 Yearly 2 Driven Shaft Assembly K9334JV Part for electrode mechanism 1 3 years O Ring Y9115XB_ Part for electrode mechanism 1 3 years Drive Belt L9804UK_ Part for electrode mechanism 1 3 years Motor Assembly 100 V K9334JY Part for electrode mechanism 1 3 years Motor Assembly 110 V K9334VQ_ Part for electrode mechanism 1 3 years Motor Assembly 200 V K9334VR_ Part for electrode mechanism 1 3 years Motor Assembly 220 V K9334VS Part for electrode mechanism 1 3 years Gear Head 100 V 110 V K9332JP
67. e ceramic beads are normally filled up to the bottommost notch of the beads case when the indicator electrode is inserted In maintenance position Electrode mechanism block Se ett otc Te a ZA 8H eninge E Ua IK Counter electrode reference electrode The bottommost notch of the beads case Indicator electrode rotating electrode fin 2 pcs a Beads case Ceramic beads Beads case cover F6 1e ai Figure 6 1 Measuring Tank Parts and Beads Case IM 12F5A1 01E lt 6 Operation gt 6 3 2 Removing the Indicator Electrode Remove the electrode mechanism block cover from the detector Hold the gears so that the drive shaft does not turn and remove the indicator electrode The electrode is screwed into the drive shaft turn the electrode counterclockwise In so doing do not touch the brush Also exercise care so that you do not touch the electrode surface of the indicator electrode electrode surface F6 4 ai Figure 6 4 Appearance of the Indicator Electrode 3 Polishing the Electrode Surface of the Indicator Electrode Spread the provided abrasive alumina onto dampened gauze and thoroughly clean the electrode surface using such gauze so that any contamination such as oil and grease is completely removed Then wash off any abrasives adhering to the electrode in clean running water After polishing and cleaning confirm that contamination has been c
68. e mechanism 1 3 years Gear Head 200 V 220 V K9334VA Part for electrode mechanism 1 3 years Activated Charcoal Filter L9862AY For zero calibration 1 Yearly Replacement intervals vary depending on the application 1 At the time of damage IM 12F5A1 01E 2 6 2 4 lt 2 Specifications gt Dimensions Unit mm n Approx 110 276 Approx 160 Maintenance space vt y A K E 2 E H C wm S D Hw oo T y i ri j A e ee ia n y i SBA l U H g Maintenance Maintenance i SE space anaes T amp lt Y Y n ue Ta BA Converter T a F 2B Fip Stanchion xci A i X A R 0 Q D 9 oO 4 y Measuring I tank 16 5 29 5 35 Electric connection 3 010 5 holes I JIS A15 plastic water proof or wall Needle valve plug or equivalent 9 Drain outlet Sample inlet Pansa 915 hose coupling Rc1 4 Figure 2 3 Dimensions of the FC400G Free Available Chlorine Analyzer IM 12F5A1 01E 3 3 1 lt 3 Installation Piping and Wiring gt 3 1 INSTALLATION PIPING AND WIRING Installation The FC400G free available chlorine analyzer non reagent type is sufficiently packed for shipment to prevent damage during transportation Upon receipt carefully unpack the FC400G
69. econds even when the time elapses for CT minutes meaning that operation is unstable error indication is generated e Setting AT SEC Stability Check Time Set the stability check time AT SEC in the range of 5 to 200 sec This parameter is set to 10 sec at factory shipment e Setting APPM Concentration Change Allowance Set the concentration change allowance APPM in the range of 0 01 to 0 05 mg l This parameter is set to 0 01 mg l at factory shipment e Setting CT min Stabilization Wait Time Set stabilization wait time CT min in the range of 0 1 to 25 0 min This parameter is set to 7 0 min at factory shipment Code 05 Selecting Linear Output Two line segment Output NONLN Mode Set the parameter to 0 to generate linear output see Figure 6 6 in the range of 0 to 100 or to 1 to generate two line segment output where output is segmented into two steps 0 to 50 and 50 to 100 This parameter is set to O linear output at factory shipment 100 100 Output Output w Mo 1 2 05 1 2 Output range mg l Output range mg l F6 6e ai Figure 6 6 Linear Output Example Figure 6 7 Two Line Segment Output Example IM 12F5A1 01E 6 12 lt 6 Operation gt 5 Code07 Setting Applied voltage Compensation Parameters DRV V Mode In the free available chlorine analyzer optimum applied voltage value changes in proportion to the diffusion current value as shown in the plateau characteristic in
70. ectrode and select CELL ON in the lt CELL gt mode Then press the key to rotate the electrode Operate the free available chlorine analyzer for approx one hour Calibration can be conducted after this approx 1 hr running in Note It is recommended that electrode polishing be performed even when calibration is performed periodically during operation However electrode polishing can be omitted if the calibration interval is short and it can be determined that the electrode is not contaminated The characteristic readings of the indicator electrode are temporarily not stable immediately after polishing the electrode Therefore after electrode polishing is performed leave the FC400G running for a while approx 1 hour under the measurement conditions until the characteristic readings of the indicator electrode stabilize Calibration is performed following this running in Zero Calibration The method of calibrating the zero point of the free available chlorine analyzer includes two approaches open input circuit and chlorine free water based measurement methods In the former the electrode is exposed in the air so that no current flows between the indicator electrode rotating electrode and counter electrode The latter uses chlorine free water e g water filtered through activated charcoal During auto zero calibration with the activated charcoal filter chlorine free chlorine not included water must be used If the FC400G ge
71. emperature effects 0 5 10 C Power variation effects 0 5 10 of rated voltage Combined chlorine effects of the combined chlorine insensitive version Approx 30 of combined chlorine concentration IM 12F5A1 01E 2 4 lt 2 Specifications gt 2 3 Model and Codes 2 3 1 Free Available Chlorine Analyzer Non Reagent Type Model Suffix Code Option Code Description FC400G Free available chlorine analyzer non reagent type Output 5 ss ww ee e 1 5V DC signal J 6 wwe enn n eee 4 20 mA DC 200 V AC 10 50 Hz 200 V AC 10 60 Hz 220 V AC 10 50 Hz 220 V AC 10 60 Hz 100 V AC 10 50 Hz 100 V AC 10 60 Hz 110 V AC 10 50 Hz 110 V AC 10 60 Hz E a eee StyleA Power supply ANOAKRWN Units in ppm With Tag Plate With ST401G Sampling system Note 1 With Teflon coated screws for protection from salt corrosion Combined chlorine insensitive version Optional specifications Note 1 Specified ST to use with sampling system Accessories Name Part No Q ty Remarks L9827AB Nominal size 1 5 mm Note1 Glass beads is used in case of combined chlorine insensitive version 2 3 2 Sampling System Model Suffix Code Option Code SEAOUG eed aneeezeeataneseanc Sampling system With free available chlorine analyze
72. es These cables are used to output lt FAIL gt and lt MAINT gt contact signals from the converter For contact output use cables with a finished O D of 9 to 12 mm select a two or four core cable depending on the number of contact outputs to be used The contact capacity of contact output relays is as shown in Table 3 1 Devices to be connected must meet the conditions in Table 3 1 Table 3 1 Contact Output Relay s Contact Capacity ror For Maximum allowable contact voltage 220 V Maximum allowable contact current 1A Maximum allowable contact power 60 W 125 VA Connect the core conductors of cables to terminals F1 and F2 lt FAIL gt contact output and to terminals M1 and M2 lt MAINT gt contact output Before connecting cables process the ends of the cables as follows Remove approx 40 mm of cable insulation covering from the end to be connected to the converter and install a crimp terminal lug for an M3 screw on each conductor IM 12F5A1 01E lt 4 Parts Names and Operations gt 4 1 4 PARTS NAMES AND OPERATIONS 4 1 Parts Names and Functions lt Detector gt Base Fixing screws indicator electrode Note1 Measuring tank Ceramic beads Polish the indicator electrode to maintain the clean surface Drain cock of the indicator electrode When loosened sample in the measuring tank drains Drive shaft Driven shaft The driven shaft is connected to the indicator electrode b
73. essage area display content Temperature diffusion current applied voltage output slope and zero point Selects HOLD ON OFF Note If HLD OF is set in the setting level entry into the HOLD mode is not available Selects cell motor ON OFF IM 12F5A1 01E 4 4 lt 4 Parts Names and Operations gt 4 2 2 Modes in Setting level Press the key to switch from Measurement to Setting mode and press the key to exit Setting and revert to Measurement mode Select the Setting mode from the following 1 OUTPU Range setting concentration values corresponding to 50 and 100 output Both range 1 and range 2 are set 2 SET HD Turn HOLD ON OFF select HOLD output previous value preset value 3 WASH Select Manual or Auto Wash select Timer ON OFF set wash interval wash time and stabilization settling time Since the FC400G does not use reagent washing is not provided and wash mode is not used in the standard instrument AZ CAL Set Auto Zero calibration select Timer ON OFF set wash interval wash time and stabilization settling time 4 PLAT Plateau characteristic measurement data read out initial applied voltage step applied voltage set number of steps 5 SERVC Enter service level code refer to Sec 4 2 3 4 2 3 Modes in Service level Enter the setting level using key Then press the key to call the lt SERVC gt mode and press the key to enter the service level The service level h
74. g 2B pipe mounting or wall mounting Weight Approx 6 kg EMC Regulatory Arrangement in Australia and New Zealand amp EN 55011 ClassA Group 1 KC Marking Korea Electromagnetic Conformity Standard Dedicated Sampling System for Non Reagent Type Free Available Chlorine Analyzer Function Used for application having high pressure and large flow rate Refer to GS 12A00V02 01E Characteristics display shows value relative to the upper limit of a range Repeatability 2 Linearity 5 Drift Zero drift 1 month Span drift 10 month Response time Approx 2 min 90 response time Temperature compensation error water temperature 3 Temperature compensation range 0 to 40 C Ambient temperature effects 0 5 10 C Power variation effects 0 5 10 of rated voltage Combined chlorine effects of the combined chlorine insensitive version Approx 30 of combined chlorine concentration IM 12F5A1 01E lt 2 Specifications gt 2 5 Model ST401G refers only to a sampling system and does not include a free available chlorine analyzer and or a pH meter sensor holder converter and ultrasonic oscillator Instrument should be purchased separately Note that the ST401G Sampling System accepts the following models of note 1 or note 2 only and depending on system configuration Note 1 Non reagent type free available chlorine analyzer refer to GS 12F5A1 E When ordering option code ST integration
75. h eis eievas vie etiaese 10 1 10 2 3 Indicator Electrode K93J3J2MB occoccocgaconucaa anaana 10 2 10 2 4 Counter Electrode K9O332MK J esoanucscnosdsosnanniane 10 2 10 2 5 Puse AIWMIEP siawsiacneeiinchutieaihutieiiiieniada 10 2 10 2 6 Brush K9332JX and Slip Ring K9332JZ cecccceseeeseseetee 10 3 10 2 7 Driven Shaft Assembly K9O334JNV oo eeeeceeeeeeeeeeeteeeteeeneeeereeteeeas 10 3 10 2 8 Drive Belt LOBQ4UK iseanan aaa aaa Ra 10 3 10 2 9 Motor Assembly See CMPL sssssssssesiesrsersersersrsrsrnsrrsensnsrrsnens 10 3 102 10 Geat Head See CMPL ruiriseniiiiiaagieaeiaaadai a 10 3 10 2 11 Activated Charcoal Filter Element L9862AY ee eeeeeeeeeteeeeeee 10 3 Customer Maintenance Parts List ccsseseseeeneees CMPL 12F05A01 01E REVISION INFORMATION cciscsicissvescsactswstdnesnsvessecedsssnnensusdhsintensvansenpuntecubidtvecneaseessets i IM 12F5A1 01E 1 lt 1 Overview gt 1 1 OVERVIEW In recent years measuring and monitoring the concentration of free available chlorine in water distribution has become increasingly important for obtaining safe drinking water The FC400G free available chlorine analyzer non reagent type is a process use free available chlorine analyzer utilizing a rotating electrode polarographic method for measurement Commercialized with minimum maintenance as a primary theme the FC400G can continuously measure the free available chlorine concentration without reagent use When
76. he electrode stops rotating the CELL lamp extinguishes Remove the electrode mechanism block from the measuring tank and set up the block as shown in Figure 8 2 The electrode mechanism block is fixed to the measuring tank using two screws at the lower part of the mechanism block Electrode mechanism block Electrode mechanism block cover Fixing screws 2 pes F6 2e ai F6 3e ai Figure 8 1 Electrode Mechanism Figure 8 2 Under Maintenance 2 Block Fixing Screws Removing the Indicator Electrode Remove the electrode mechanism block cover from the detector Hold the gears so that the drive shaft does not turn and remove the indicator electrode The electrode is screwed into the drive shaft turn the electrode counterclockwise In so doing do not touch the brush Also exercise care so that you do not touch the electrode surface of the indicator electrode electrode surface Q gt F6 4 ai Figure 8 3 Appearance of the Indicator Electrode 3 Polishing the Electrode Surface of the Indicator Electrode Spread the provided abrasive alumina onto dampened gauze and thoroughly clean the electrode surface using such gauze so that any contamination such as oil and grease is completely removed Then wash off any abrasives adhering to the electrode in clean running water After polishing and cleaning confirm that contamination has been completely removed The clean electrode surface must be uniformly wetted Note Pol
77. heck if the drive belt teeth are badly worn If so replace it e Check if powder from the drive belt is stuck to drive shaft or driven shaft If this powder is adversely affecting pulley operation remove for cleaning When cleaning the pulley also clean powder from the drive belt off the motor mounting plate Replacing the Drive Belt When replacing the drive belt the tension in the drive belt needs to be adjusted or the drive belt like may be adversely affected Because this adjustment is rather time consuming and troublesome it is recommended that where possible except when the drive belt is no longer rotating the electrode reliably and needs to be urgently fixed the driven shaft assembly and motor be replaced at the same time as the drive belt If you want to replace just the drive belt refer to Sec 8 2 3 14 and 15 IM 12F5A1 01E lt 8 Maintenance gt 8 7 8 2 3 Check Maintenance Replacement of Driven Shaft Assembly Checks and Maintenance At zero calibration time operate the indicator electrode and check the following once in three months recommended Check if noisier that usual or if vibration or non continuous noises If sound is abnormal driven shaft assembly may be bad or problem may be in motor Stop electrode rotation check if bearing at bottom of driven shaft is gone see six monthly check below Check if vibration in driven shaft or indicator electrode Usually the bushing bearing
78. ibed in Sec 7 2 1 is performed the FC400G is in the MEAS mode or in the lt HOLD gt mode and SPAN is not displayed Refer to b in Sec 5 4 1 and display SPAN in the lt CAL gt mode 1 Press the key to enter the span calibration mode Free chlorine concentration is displayed in the data display 2 Collect sample water for performing manual analysis Confirm that the free chlorine concentration of the sample water remains stable before span calibration is finished Collect sample water for performing manual analysis by opening the drain cock on the measuring tank Collect sample water while observing the liquid surface in the measuring tank to make sure the tip of the counter electrode silver chloride electrode is not exposed to the air Note If the counter electrode is exposed to the air the reading will drop to zero and when the counter electrode is re immersed into the sample water it will take some time usually several minutes before the reading stabilizes If it is accidentally exposed to the air confirm that the reading has returned to the original value and is stable and perform the operation in item 4 3 Measure the free chlorine concentration of the sample water using manual analysis e g an amperometric titration method The free chlorine concentration of the sample water changes over time Perform manual analysis immediately after collecting sample water 4 Enter the obtained value in the data displ
79. ice code 08 exceeds the range of 50 to 120 when the slope is confirmed during calculation in span calibration The calibration standard solution used for span calibration may have aged entering the incorrect concentration value or the indicator electrode may have deteriorated Confirm the presence of any of these If the error still fails to extinguish even when re calibration is made using a new calibration standard solution or after the indicator electrode has been polished using alumina the indicator electrode must be replaced Err 6 Zero Point Error Err 6 appears if the zero point exceeds 1 00 uA when the zero point is confirmed during calculation in zero calibration Chlorine may enter the chlorine free water used for the calibration when the chlorine free water based measuring method applies or the indicator electrode or counter electrode may be defective Confirm if any of these is the cause Err 7 Response Error during Zero and or Span Calibration Err 7 appears if concentration does not stabilize within CT min stabilization setup time set in service code 04 during zero and or span calibration Confirm response recovery after the indicator electrode has been polished using alumina Also confirm that the set values of stability determination parameters AT SEC APPM and CT min set in service code 04 are correct If the parameters are correct but still no respo
80. ided for the FC400G The same applies to glass beads K9332ZJ used in to decrease influence of combined chlorine insensitive version IM 12F5A1 01E 1 0 2 lt 10 Spare Parts and Consumables gt 10 2 3 Indicator Electrode K9332MB The indicator electrode is always polished with ceramic beads it gradually wears and ultimately becomes unusable This is the primary factor determining the life of the electrode Recommended replacement interval of the indicator electrode is one year generally The abrasion based life may be used as a guidance in providing for indicator electrode replacement However recommended practice is to keep one spare always available since the electrode could be inadvertently damaged or otherwise become defective The same applies to gold alloy indicator electrode K9334JP used in combined chlorine insensitive version Note Refer to the following cool storage requirements for electrically conductive silicon grease for indicator electrode Applying Electrically conductive Silicon Grease to Indicator Electrode The indicator electrode needs to be electrically connected to the driven shaft This is achieved by applying electrically conductive silicon grease to the tapped part of the indicator electrode Before use check that this has been done If not apply silicon grease as follows You can purchase 3 ml tubes of conductive silicon grease from Yokogawa the part no is K9044FX Be careful not t
81. iffusion current applied voltage output slope and zero point lt OUTPU gt Output range setting Mode e Range 1 Setting corresponding to 50 output 1 00 mg L 0 00 to 3 00 mg L Setting corresponding to 100 output 2 00 mg L 0 00 to 3 00 mg L e Range 2 Setting corresponding to 50 output 1 00 mg L 0 00 to 3 00 mg L Setting corresponding to 100 output 2 00 mg L 0 00 to 3 00 mg L lt SET HD gt Hold Parameter Setting Mode e Output hold ON OFF selection ON HLD ON ON HLD ON OFF HLD OF e Hold output value selection Value immediately Value immediately preceding preceding hold HD LST hold HD LST Fixed value HD FIX e Setting of fixed value HOLD 50 0 0 0 to 100 0 lt WA CA gt Wash Auto zero Calibration Mode etting lt WASH gt Washing Mode e Washing timer ON OFF selection Timer OFF T OFF Timer ON T ON Timer OFF T OFF e Washing interval setting INT H 2 0 hr 0 1 to 24 0 hr e Washing time setting WT min 1 0 min 0 1 to 25 0 min e Releasing time setting RT min 5 0 min 0 1 to 25 0 min lt AZ CAL gt Auto zero Calibration Mode e Calibration timer ON OFF selection Timer OFF T OFF Note Timer ON OFF e Calibration interval setting INT D 10 0 days 0 1 to 99 9 days e Calibration setup time setting WT min 010 min 1 t
82. ine analyzer is specified singly or in combination with pH meter by suffix code FC4 Available when free available chlorine analyzer is specified singly by suffix code FC4 An arrester is supplied automatically Name Part No Description Q ty ede ea Indicator Electrode Rotating electrode K9332MB Gold electrode 1 Yearly Indicator Electrode Rotating electrode K9334JP Gold alloy indicator electrode 1 Yearly Counter Electrode K9332MK Silver chloride electrode 1 1 Ceramic Beads K9332ZP ere ll type indicator elec 1 Yearly Glass Beads K9332ZJ For cleaning combined chlorine insensitive 1 Yearly type indicator electrode 2 bags 1Q ty Polishing Powder Alumina K9088PE For polishing indicator electrode 1 Yearly Brush K9332JX Part for electrode mechanism 1 2 years Slip Ring K9332JZ Part for electrode mechanism 1 2 years Fuse A1111EF 2A 1 Yearly Driven Shaft Assembly K9334JV Part for electrode mechanism 1 3 years O Ring Y9115XB_ Part for electrode mechanism 1 3 years Drive Belt L9804UK Part for electrode mechanism 1 3 years Motor Assembly 100 V K9334JY Part for electrode mechanism 1 3 years Motor Assembly 110 V K9334VQ_ Part for electrode mechanism 1 3 years Motor Assembly 200 V K9334VR_ Part for electrode mechanism 1 3 years Motor Assembly 220 V K9334VS Part for electrode mechanism 1 3 years Gear Head 100 V 110 V K9332JP Part for electrod
83. into ST401G sampling system must be specified Note 2 4 wire type pH converter system refer to GS 12B7C1 E GS 12B07C05 01E GS 12B07B02 E GS 12J05C02 00E pH sensor PH8EFP 03 TN TT1 N T A when suffix code of PH4 PF4 specified PH8EFP 03 TN TT3 N T A when suffix code of PH4 PF4 and option code of TT3 specified PH8EFP 03 TN TT1 N G A when suffix code of PH5 PF5 specified PH8EFP 03 TN TT3 N G A when suffix code of PH5 PF5 and option code of TT3 specified pH holders PH8HF PP JPT T NN NN A without cleaning system PH8HF S3 JPT T NN NN A without cleaning system PH8HF PP JPT T S3 C1 A with ultrasonic cleaning PH8HF S3 JPT T S3 C1 A with ultrasonic cleaning pH converter PH400G O EA B when suffix code of PH4 PF4 specified PH450G A E when suffix code of PH5 PF5 specified Ultrasonic oscillator PUS400G NN NN L E which power supply rating should be same as the pH converter Note 3 Power supply rating of non reagent type free available chlorine analyzer should be same as the pH converter Note 4 Specify if needed instead of the standard stanchion made of carbon steel Note 5 Available only when the suffix code FC4 PH4 or PH5 is specified Note 6 Available when free available chlorine analyzer is specified singly or in combination with pH meter by suffix code FC4 PF4 or PF5 Not
84. ion Interval INT D 10 days refer to zero filter flushing functions for Calibration Setup time WT min 10 min for Stabilization settling time RT min 10 min When Auto Zero Calibration starts the analog output is held lt HOLD gt lights and lt CAL gt blinking is displayed At the same time the lt MAINT gt contact output turns ON After the calibration setup time has elapsed the measured value drops to near zero and after this measured value has stabilized it is automatically reset to zero The method used to determine if the value has stabilized is the same as for manual calibration When calibration is completed the flow through the unit is switched from zero water pure deionized water to sample water then after the stabilization settling time has elapsed the analog output hold is released lt HOLD gt and lt CAL gt go OFF and the lt MAINT gt contact turns OFF IM 12F5A1 01E 7 4 lt 7 Calibration gt AY NOTE 1 During Auto calibration if the key or key are pressed then Auto calibration is aborted and immediately the analog output hold is released lt HOLD gt and lt CAL gt go OFF and the lt MAINT gt contact output goes OFF The calibration interval timer is reset to zero 2 When the following conditions are true the calibration interval timer starts to count from 0 to its count up setting e When the unit was started up with Auto zero calibration turned ON e When Auto
85. ish the electrode surface by following the instructions below when it has become corrugated IM 12F5A1 01E or deformed from the original shape about 3 mm in diameter Polish the electrode surface with sandpaper about 600 until the surface becomes finely rounded Then polish it with sandpaper about 2000 and lastly with polishing powder alumina Make sure the electrode surface is clean and then install the indicator electrode Reduce the amount of ceramic beads if the electrode has deformed greatly The ceramic beads are normally filled up to the bottommost notch of the beads case when the indicator electrode is inserted lt 8 Maintenance gt 8 3 4 Installing the Indicator Electrode Hold the gears so that the drive shaft does not turn and sufficiently screw the electrode into the shaft During installation exercise care not to touch the electrode surface Note Polish the electrode surface again if you have touched it Cleaning the Ceramic Beads and Measuring Tank Contaminated ceramic beads reduces the effects of cleaning of the indicator electrode and may possibly cause electrode contamination Clean the ceramic beads periodically Also simultaneously clean the measuring tank Clean them as follows 1 Turn OFF the power switch provided in the power line or remove the fuse provided in the converter to stop the free available chlorine analyzer Note Be alert to the fact that even if the fuse is removed live voltage
86. leys on driven shaft and drive shaft Remove slip ring from driven shaft Remove the plate installed to prevent drive belt shavings to enter the electrode holder in the driven shaft assembly by loosening the 2 screws Remove two plates which holds driven shaft assembly in place If driven shaft assembly is bad remove it from motor mounting plate The place where the electrode holder base is inserted contains an O ring This O ring and the counter electrode fixing clamp can be reused Note Even if the O ring part no Y9115XB is not damaged it is recommended to replace it after 3 years use The following from item 10 below onwards is the procedure for reassembly When reassembling observe the following cautions Clean any dirt off parts before reassembling Adjust drive belt tension to 4 N 0 4 kgf When reassembling make sure that indicator electrode does not make contact with its base IM 12F5A1 01E 8 8 lt 8 Maintenance gt 10 Assemble new driven shaft assembly on motor mounting plate First install the clamp and O ring in the electrode holder in the driven shaft assembly The O ring should be installed in the position of approximately 4 mm from the end of the electrode holder Next mount the driven shaft assembly on the motor mounting plate taking care not to allow the O ring to protrude from the hole in the base 11 Mount plate that holds driven shaft assembly in place Confirm that four pins on plate su
87. lly check the driven shaft slip ring and the brush contacting the ring for abnormalities such as abrasion Further measure resistance between the brush wiring terminal and driven shaft using a tester It is acceptable when the resistance is 500 Q or less with the indicator electrode operating If the resistance exceeds 500 Q remove any grime from the slip ring using an alcohol dampened cotton swab and re measure the resistance If abnormality such as slip ring wear or bent brush is detected or if the resistance between the brush wiring terminal and driven shaft is unable to recover to below 500 Q the slip ring and brush must be replaced In general contact Yokogawa service for their replacement Drive belt Pulleys Driven shaft Drive shaft Brush Brush fixing screw Rock screw Slip ring a Contact pressure adjusting screw Gear head Plate Cell motor Clamp Electrode holder Counter electrode Indicator electrode F8 1e ai Figure 8 5 Electrode Mechanism Block If they are replaced by the customer follow the steps below 1 Shut off the power fed to the free available chlorine analyzer to stop the operation 2 Remove the brush by unscrewing the two screws firing the brush one of them is also used as wiring terminal 3 Remove the two pulleys of the drive shaft cell motor shaft and driven shaft indicator electrode mounting shaft The driven shaft pulley can be removed by inserting a 2 mm no
88. ls must be determined in accordance with individual operating conditions Table 8 1 Inspection and Maintenance Items and Implementation Cycle Inspection and Maintenance Items Implementation Cycle e Polishing of indicator electrode Monthly e Replacement of indicator electrode Once a year e Ceramic beads cleaning Every 3 months e Replacement of ceramic beads Once a year e Measuring tank cleaning Every 3 months e Calibration Monthly e Replacement of activated charcoal filter Once a year Note Appropriate maintenance intervals must be determined in accordance with the condition or contamination Same applies to decrease of influence of combined chlorine insensitive version with gold alloy electrode and glass beads Polishing the Indicator Electrode The indicator electrode constantly rotates at 600 rpm at 50 Hz and is automatically continuously polished with ceramic beads However this does not completely prevent adhesion of contamination contamination gradually accumulates on the electrode surface over time Acontaminated electrode surface is a cause of measurement error The degree of this measurement error increases depending on the amount of contamination Therefore the electrode surface must be polished using abrasive alumina to remove such contamination before measurement error exceeds the allowance Polishing frequency differs with the quality of the sample water Polishing every a few months may be sufficient in some c
89. lues corresponding to outputs of 100 for both ranges 1 and 2 When two line segment output is selected using SERVICE code 05 and remote range switching is also turned ON using SERVICE code 10 then set the concentration values corresponding to outputs of 50 and 100 for both ranges 1 and 2 Shipping time default settings are Range 50 1 00 mg L 100 2 00 mg L Range2 50 1 50 mg L 100 3 00 mg L Hold Parameters Setting lt SET HD gt Mode Set various data for hold of output during maintenance e Output Hold ON OFF Selection Select HLD OF to disable output hold or HLD ON to enable output hold during maintenance e Selecting HLD ON causes output to be automatically held during calibration of zero point and or span automatic washing and entry into the setting level by pressing the key Further output hold can be manually made in the lt HOLD gt mode in the operation level When the FC400G is in hold status appears on the LCD Note Selection of HLD OF in the setting level disables entry into the lt HOLD gt mode in the operation level e Hold Output Value Selection when HLD ON is selected Select HD LST to set the value immediately preceding hold as hold output value or HD FIX to set a fixed output value preset value e Setting the fixed Output Value when HD FIX is selected Set fixed output value in the range of 0 0 to 100 0 At factory shipment the fixed output value is set to 50 0 Wash Auto ze
90. minal size Allen wrench accessory into the hole in the shaft which is used as a lock and unscrewing the end of the driven shaft The drive shaft pulley can be removed by unscrewing two set screws using a 1 5 mm nominal size Allen wrench accessory Remove the pulleys together with the drive belt IM 12F5A1 01E 8 6 8 2 2 lt 8 Maintenance gt 4 Remove the slip ring from the driven shaft and attach a new one onto the shaft 5 Install the pulleys and drive belt in place Note Mount the drive shaft pulley so that it is 0 3 to 0 7 mm from end of the shaft 6 Install a new brush taking care not to deform it Locate the hole in the brush to the positioning pin on the bracket and fix the brush using the two fixing screws After installation check that the probe at the tip of the brush contacts the slip ring and that the brush body does not contact the pulley If the brush probe does not contact the slip ring the position of the brush mounting bracket must be adjusted so that the probe contacts the slip ring Adjust the contact pressure of the brush First loosen the two screws fixing the brush mounting bracket and also the lock screw next to the contact pressure adjusting screw Then by pulling the brush mounting bracket towards you screw in the contact pressure adjusting screw The desirable screwing amount of the contact pressure adjusting screw can be obtained when the screw is tightened by three and half
91. n the electrode surface using such gauze so that any contamination such as oil and grease is completely removed Then wash off any abrasives adhering to the electrode in clean running water After polishing and cleaning confirm that contamination has been completely removed The clean electrode surface must be uniformly wetted A IMPORTANT Polish the electrode surface gold electrode by following the instructions below when it has become corrugated or deformed from the original shape about 3 mm in diameter Polish the electrode surface with sandpaper about 600 until the surface becomes finally rounded Then polish it with sandpaper about 2000 and lastly with polishing powder alumina Make sure the electrode surface is clean and then install the indicator electrode Reduce the amount of ceramic beads if the electrode has deformed greatly The ceramic beads should be filled up to 5 mm under the bottommost notch of the beads case when the indicator electrode is inserted IM 12F5A1 01E lt 8 Maintenance gt 8 3 4 Installing the Indicator Electrode Hold the gears so that the drive shaft does not turn and sufficiently screw the electrode into the shaft During installation exercise care not to touch the electrode surface Note Polish the electrode surface again if you have touched it Cleaning the Ceramic Beads and Measuring Tank Contaminated ceramic beads reduces the effects of cleaning of the indicator electrode
92. nerally measures free chlorine concentrations as low as 0 1 mg l conduct zero calibration using the chlorine free water based measuring method However the open input circuit method easy to conduct is generally used IM 12F5A1 01E 7 2 lt 7 Calibration gt 7 2 1 Method of Zero Calibration using Open Input Circuit Method This section describes zero calibration using open input circuit method 1 Note This section also explains how to stop the indicator electrode when electrode mechanism block is moved It is not necessary to stop the indicator electrode for the purpose of calibration but rather _ before lifting out the electrode mechanism block or moving the unit _ to eliminate the chance of the electrode hitting something while rotating Before lifting the electrode mechanism block from the measuring tank stop the electrode rotation In lt CELL gt mode of Operation Level CELL ON displayed in message display press the key Stopping the electrode rotation turning drive motor power OFF results in the CELL display disappearing Place the electrode in its maintenance position see Figure 7 1 and start it rotating again Loosen the two screws that fix the electrode mechanism block to the measuring tank and lift it vertically to remove it from the tank After resting the block in its maintenance position pressing the key in lt CELL gt mode restarts electrode rotation and the CELL display is lit
93. ng YES or NO MODE Used to select to operation mode from measurement mode or A to return measurement mode from modes of each level D CD Used to set data D Oe OR ORC ENT D Pressing this key sets an entered value x C Used to select the setting level from MEASURE mode F5 1e ai IM 12F5A1 01E 5 2 lt 5 Key Operation and Display gt 5 2 Display Content on the Display Unit Data Area ra o FD Mode Pointer Modes in the Operation Level Message Indicator Operation Key Indicator MODE MEASURE CAL OUTPUT DISP i SET HOLD WASH CAL PLATEAU SERVICE CONTACTS O FAIL O MAINT O WASH CAL O CELL I 1 1 1 ros 1 1 1 9 F5 2e ai Displays measured data and set data Appears if the FC400G is in hold status Appears if failure occurs Points to the currently selected mode When the pointer is lit it indicates that the relevant mode has been selected If the pointer blinks it indicates that the FC400G is not yet in that mode Displays data other than the measured concentration value and messages required for interactive operation Note Appearance of at the head of a message means that the FC400G is in the setting service level Indicates key s required for interactive operation with respect to the displayed message Types of Modes in the Setting Level Service Level Operation Status Display LED IM 12F5A1 01E Di
94. normal e Failure caused by any usage out of scope of recommended usage e Any damage from fire earthquake storms and floods lightning disturbances riots warfare radiation and other natural changes Yokogawa does not warrant conformance with the specific application at the user site Yokogawa will not bear direct indirect responsibility for damage due to a specific application Yokogawa Electric will not bear responsibility when the user configures the product into systems or resells the product Maintenance service and supplying repair parts will be covered for five years after the production ends For repair for this product please contact the near est sales office described in this instruction manual IM 12F5A1 01E lt CONTENTS gt vV Model FC400G Free Available Chlorine Analyzer Non Reagent Type IM 12F5A1 01E 4th Edition CONTENTS INTRODUCTION ices sit ceent huss ccirenncaetstunctpavendaai ant aaan panedana audia iNi adaa i 1 OVERVIEW icuctestnasitintre tcl dcsa cannes ach cunesiese darniewepacecuaieastenbecceauneniecattodny seen oes 1 1 1 1 Configuration of the Free Available Chlorine Analyzer cscseeeeeee 1 2 1 2 Measuring Principle of FC400G Free Available Chlorine Analyzer 1 3 2 SPECIFICATIONS ioccicsccecistaccactesesacc andes caste eweceamisnaiaiian dap aaea a aaia 2 1 2 1 Standard Specifications ccscsscsscsscsceseesesseeseneesseeenenenseseeeseenneseeseeenennes 2 1 2 1
95. nse recovery the indicator electrode may have deteriorated Replace the indicator electrode Err 8 Temperature Compensation Range Exceeded Err 8 appears if sample temperature exceeds the temperature compensation range of 0 0 to 40 0 C Control sample temperature to be in the range of 0 0 to 40 0 C Note Exceeded temperature compensation range check is available only when temperature compensation range fail ON is selected in service code 02 IM 12F5A1 01E lt 9 Troubleshooting gt 9 3 Err 10 Converter failure The FC400G free available chlorine analyzer has become defective Contact Yokogawa service NOTE 01 Input Data Setting Range Exceeded This error appears if a set value exceeds the relevant setting range when data is set in the operation level setting level or service level If this error message appears the relevant data will not be updated Set correct value again NOTE 02 Input Data Setting Error This error is generated if the mg l or ppm value for 100 signal output falls below 1 00 mg l or 1 00 ppm in the lt OUTPU gt mode in the setting level If this error message appears the relevant data will not be updated Set correct value again NOTE 03 Input Data Setting Error This error is generated if the mg l or ppm value for 100 signal output is set to a value below the value for 50 signal output when two line segment output is set in service code 05 in the lt OUTPU gt mode in
96. nt After completion of setting of the noted parameters START appears on the LCD Then press the key This starts plateau characteristic collection IM 12F5A1 01E lt 6 Operation gt 6 11 6 3 3 Setting in the Service Level Press the key to enter the service level on SERVC display in Setting Level Enter a code in the service level to enter the service mode 1 2 4 Code 01 Selecting Temperature Unit C F TEMP Mode Set temperature unit to O to apply C or 1 to use F This parameter is set to 0 C at factory shipment Code 02 Selecting Exceeded Temperature Compensation Range Check ON OFF FAIL Mode Note The left digit of two digit figures is the reserved code This does not affect operation whether it is 0 or 1 To check if sample water temperature is in the temperature compensation range 0 to 40 C set the right digit of the figures to 1 Set it to 0 when not conducting a check When this parameter is set to 1 conducting the check fail contact output becomes ON if sample water temperature exceeds the temperature compensation range This parameter is set to 0 no check at factory shipment Code 04 Setting Stability Determination Parameters AT SEC Mode Set parameters APPM AT and CT used to determine if electrode operation is stable during zero point and or span calibration If concentration changes by APPM mg l or more during AT s
97. nt continuity is obtained to this terminal to provide grounding grounding resistance of 100 Q or less Note If grounding using the converter case grounding terminal is difficult connect the grounding wire to terminal G M3 screw in the converter to make grounding on the power side This requires that a three core or two core shielded cable be used as a power grounding cable Analog Output Signal Cable An analog output signal cable is used to transmit an output signal of 1 to 5 V DC or 4 to 20 mA DC corresponding to the output range to a receiver such as a recorder For analog output signals use a two core shielded cable with a finished O D of 9 to 12 mm Process the end of the cable to be connected to the converter as follows 1 Remove insulation covering and shield from the cable up to approx 40 mm from the end of the cable Solder a lead wire to the root of the exposed shield and protect the soldered area by wrapping with insulation tape 2 Cut the lead wire to the length of the core conductors and connect a crimp terminal lug for with M3 screws to the end of this lead wire and the conductors 3 Connect the cable to the converter s terminals and the positive side conductor of the cable must be connected to the of the OUTPUT terminal and the negative side conductor to the of the OUTPUT Also connect the shield lead wire to terminal G Do not attempt to ground the shield on the receiver side Contact Output Cabl
98. o 100 min e Stabilization settling time setting RT min 010 min 1 to 100 min lt PLAT gt Plateau Measurement Mode e Initial applied voltage setting INI V 1 00 V 1 00 to 1 00 V e Step applied voltage setting STPV 0 20 V 1 00 to 1 00 V e Step count setting STP NO 10 steps 1 to 20 steps Note If you order the AZC option Timer ON T ON is the default IM 12F5A1 01E lt 6 Operation gt 6 7 Table 6 2 Setting Item List Set Values at Shipment and Their Setting at Range 2 Initial Value Setting Item at Factory Shipment Selection and Setting Range Code 01 TEMP Mode e Temperature unit selection C 0 C 0 F 1 Code 02 FAIL Mode Reserved code 0 0 1 Successive operation is not affected whether 0 or 1 is selected Selection of temperature compensation OFF 0 OFF 0 ON 1 range exceeding fail contact output ON OFF Code 04 AT SEC Mode Setting of stability determination parameter 10 sec 5 to 200 sec AT SEC Setting of stability determination parameter 0 01 mg l 0 01 to 0 05 mg l APPM Setting of stability determination parameter 7 0 min 0 1 to 25 0 min CT min Service Level Code 05 NONLN Mode Selection of linear output two line segment Liner output 0 Linear output 0 output Two line segment output 1 Code 07 DRV V Mode Setting of applie
99. o get this grease on the outer surface particularly the gold surface Apply a small quantity half a drop of grease to a small flat screwdriver about 3 mm wide blade and apply to three equidistant places around the tapped hole about 3 to 5 mm inside the tip Next screw the indicator electrode into this tapped threaded hole Next unscrew the electrode and check that no grease has been extruded to the outer surface If it has remove it with a cloth that has been wetted with alkaline soap solution AN NOTE If the conductive silicon grease gets on the electrode surface then measurement accuracy is likely to be affected Conductive silicon grease needs to be applied only once 10 2 4 Counter Electrode K9332MK The counter electrode does not wear like the indicator electrode it can be continuously used without replacement However recommended practice is to keep one spare always available in case of accidental breakage 10 2 5 Fuse A1111EF Yearly fuse replacement in the converter is recommended to avoid unexpected operation stoppage Note Fuse may be used more than one year we recommend periodical replace for planning maintenance IM 12F5A1 01E
100. ock 1 3 years Drive Belt L9804UK Part for electrode mechanism block 1 3 years Motor Assembly 100 V K9334JY Part for electrode mechanism block 1 3 years Motor Assembly 110 V K9334VQ_ Part for electrode mechanism block 1 3 years Motor Assembly 200 V K9334VR_ Part for electrode mechanism block 1 3 years Motor Assembly 220 V K9334VS Part for electrode mechanism block 1 3 years Gear Head 100 V 110 V K9332JP Part for electrode mechanism block 1 3 years Gear Head 200 V 220 V K9334VA Part for electrode mechanism block 1 3 years Activated Charcoal Filter L9862AY For zero calibration 1 Yearly Replacement intervals vary depending on the application 1 Fuse may be used more than one year we recommend periodical replace for planning maintenance 10 2 Spare Parts 10 2 1 Polishing Powder K9088PE Used to remove contamination on the indicator electrode that cannot be removed by automatic cleaning using glass beads ceramic beads One bag of abrasive is provided for the FC400G 10 2 2 Ceramic Beads K9332ZP Used to replenish or replace the ceramic beads used for automatic cleaning of the indicator electrode when their amount diminishes below the specified level or their contamination can no longer be removed The amount of the beads for replenishment or replacement differs with the FC400G operating conditions Generally approx one to two bags of beads per year are required One bottle of ceramic beads is prov
101. ompletely removed The clean electrode surface must be uniformly wetted Note Polish the electrode surface gold electrode by following the instructions below when it has become corrugated or deformed from the original shape about 3 mm in diameter Polish the electrode surface with sandpaper about 600 until the surface becomes finally rounded Then polish it with sandpaper about 2000 and lastly with polishing powder alumina Make sure the electrode surface is clean and then install the indicator electrode Reduce the amount of ceramic beads if the electrode has deformed greatly The ceramic beads should be filled up to 5 mm under the bottommost notch of the beads case when the indicator electrode is inserted 4 Installing the Indicator Electrode Hold the gears so that the drive shaft does not turn and sufficiently screw the electrode into the shaft During installation exercise care not to touch the electrode surface Note Polish the electrode surface again if you have touched it 5 Attach the electrode mechanism cover Then set the electrode mechanism block to the measuring tank in place and fasten it using the fixing screws Finally use the lt CELL gt mode in the operation level to rotate the electrode Supplying Power Before supplying power check that the fuse holder cap in the converter is not loose A power switch in the power line to the FC400G is used to turn power ON OFF the FC400G does not have any internal
102. ot have any internal power switch Be careful not to turn on the power and cause an accident with the indicator electrode or belt used to rotate it when the cover is removed or the electrodes are parked in the maintenance position shown in Figure 6 3 Note When power is supplied the instrument enters measurement mode IM 12F5A1 01E 6 4 6 1 6 lt 6 Operation gt Checking Electrode Mechanism Block Check as follows that the electrode rotates normally Put the electrode in the maintenance position Figure 6 3 or lift the cover and check the following e There should be only a slight sound from the belt or axles when the electrode rotates There should not be any sound like items making contact or vibrating There should be no unevenness or vibration The drive belt should not be visibly loose resulting in a loss of traction Replace the electrode mechanism block in the measuring tank after confirming that there are no problems After replacing the electrode mechanism block in the tank attach the cover Stop the rotation of the electrode Switch the converter to lt CELL gt mode display CELL ON and press key to stop cell motor and thus electrode rotation Mount electrode mechanism block on measuring tank and tighten fixing screws sufficiently Then press in CELL mode to start electrode rotation When the indicator electrode is rotating cell motor power is supplied from converter then CELL is displayed on CONTA
103. our FC400G Free Available Chlorine Analyzer Non Reagent Type The User s Manual IM12F5A1 01E 4th edition supplied with this product has been amended as follows please make a note in your copy Revisions Page 2 3 Some revision of 2 1 Standard Specifications EMC Australia and New Zealand and KC Marking added Page 2 5 Some revision of 2 3 3 Spare Parts Page 6 1 Some revision of 6 1 2 Filling with Ceramic Beads for Electrode Polishing Page 6 3 Some revision of 6 1 4 Polishing the Indicator Electrode Page 8 2 Some revision of 8 1 1 Polishing the Indicator Electrode Page 8 3 Some revision of 8 1 2 Cleaning the Ceramic Beads and Measuring Tank Page 8 9 Some revision of 8 2 4 Check Maintenance Replacement of Motor and Gear Head Page 10 1 to 10 2 Some revision of 10 SPARE PARTS AND CONSUMABLES YOKOGAWA amp All Rights Reserved Copyright 2012 5th Edition Jan 2014 YK IM 12F5A1 01 E Subject to change without notice 4th Edition Yokogawa Electric Corporation 2 2 lt 2 Specifications gt 2 3 Ambient humidity 5 to 95 RH no dew condensation allowed Storage Temperature 30 to 70 C Installation Indoor Outdoor use separately requires rainproof measures Direct sunlight must be avoided Utility Power supply 100 V AC 10 50 60 Hz 110 VAC 10 50 60 Hz 200 V AC 10 50 60 Hz 220 V AC 10 50 60 Hz Power consumption Approx 15 VA Mountin
104. output signal yy e F3 5e ai ao Contact output MAINT Cable inlet Contact output FAIL Power input m mM OOQWDYD Figure 3 5 Converter s External Wiring Terminal Board and Cable Inlet The converter has five external wiring cable inlets In general use one cable for each wiring line Note Unused cable inlets must always be provided with cable gland with blind plug IM 12F5A1 01E 3 3 1 3 3 2 3 3 3 lt 3 Installation Piping and Wiring gt 3 5 Power Cable and Grounding Wire A power cable is used to feed power whose voltage and frequency meet the specifications for the FC400G free available chlorine analyzer converter and a grounding wire to ground the converter case For the power cable use a two core cable with a finished O D of 9 to 12 mm to connect the power supply to converter terminals L1 and L2 The converter has no power switch it is recommended that a double pole single throw switch be installed in the power line Process the end of the cable to be connected to the converter as follows 1 Remove insulation covering from the cable for approx 80 mm from the end of the cable 2 Connect crimp on terminal lugs for M3 screws to the ends of the core conductors Install a grounding wire using the grounding terminal on the left bottom of the converter case The grounding terminal uses an M4 screw Connect a grounding conductor that is has been terminated is a lug so that sufficie
105. p ring electrode mechanism block see Sec 10 2 6 3 b Replace the brush and slip ring see Sec 8 2 1 4 Input circuit current leaks 4 Check the electrode mechanism block to correct poor insulation Example of check point insulation between the brush and base Measurement error 1 Indicator electrode has been 1 Polish the indicator electrode in is large contaminated accordance with Sec 8 1 1 also clean the ceramic beads in accordance with Sec 8 1 2 if itis not possible to sufficiently clean the beads replace them with new ones 2 Zero and or span has not been 2 Conduct zero and or span calibration correctly adjusted 3a Replace activated charcoal filter 3 Auto zero calibration abnormal 3b Piping related to auto zero calibration is blocked Measured value 1 Indicator electrode does not rotate at 1 Check if the set screws have loosened fluctuates largely constant speed Also check if the belt is normal If not replace the belt 2 Insufficient continuity between the 2 a Adjust the brush contact pressure and contact brush and slip ring at the remove wear debris from the slip ring electrode mechanism block see Sec 10 2 6 2 b Replace the brush and slip ring see Sec 8 2 1 Measured value 1 Measuring tank has no sample 1 Repair abnormality such as piping does not vary water disconnection or sample water feed failure to normal condition 2 Electrode to electrode circuitis open 2 Repair open ci
106. ping will depend on the sampling equipment When the ST401G sampling system is to be used refer to its instruction manual IM12A0V2 E Figure 3 3 shows an example of piping for the ST401G Sampling System For details refer to IM 12A0V2 E Sampling System Piping diagram of ST401G FC4 N A With free available chlorine analyzer lt Tubing materials gt H 66 04 Polyethylene tube 12 9 Polyethylene tube o lt s 22 15 soft tube with net __ VP16 Pipe VP40 Pipe Fcc FCD PR1 Pressure reducing valve FCC Free available chlorine converter 4 FCD Free available chlorine detector NV1 Needle valve E Be BV1 Ball valve SHX 0 Measuring water ra XDA tt VP16 BV1 a y 5 PVC tray Drain VP40 Piping diagram of ST401G FC4 N A AZCLU With auto zero calibration for free available chlorine analyzer lt Tubing materials gt t t __ 66 4 Polyethylene tube s 8 22 15 soft tube with net x x VP16 pipe VP40 pipe BV1 2 3 Ball valve FCC FCD PR1 Pressure reducing valve FCC Free available chlorine converter 4 i FCD Free available chlorine detector NV1 Needle valve l F1 Activated charcoal filter sv1 3 way solenoid valve i 5 FX i z C BV3 HDS O i Measuring water a ee COM O nent xD i tt Be tt NC BV1 PR1
107. r FC400G note 1 With pH converter PH400G note 2 With pH converter PH450G note 2 With free available chlorine analyzer FC400G and pH converter PH400G note 1 note 2 note 3 AE ANa With free available chlorine analyzer FC400G and pH converter PH450G note 1 note 2 note 3 Ultrasonic oscillator J N J hee Not supplied for pH meter Supplied Always A Description System note 3 Option Piping connections on the back Without instrument With stainless steel stand note 4 With arrester power and signal lines only note 5 With auto zero calibration for 100 V AC note 6 With auto zero calibration for 110 V AC note 6 With auto zero calibration for 200 V AC note 6 With auto zero calibration for 220 V AC note 6 With remote range switching note 7 With stainless tag plate With 500 ml KCI reserve tank for pH sensor note 2 IM 12F5A1 01E 2 5 lt 2 Specifications gt Model ST401G refers only to a sampling system and does not include a free available chlorine analyzer and or a pH meter sensor holder converter and ultrasonic oscillator Instrument should be purchased separately Note that the ST401G Sampling System accepts the following models of note 1 or note 2 only and depending on system configuration Note 1 Non reagent type free available chlorine analyzer refer to GS 12F5A1 E When ordering option code
108. rcuit If open circuit occurs in an electrode replace such electrode 3 No voltage is applied between the 3 Check the converter indicator and counter electrodes Abnormal analog 1 Lead resistance is too large 1 Reduce the resistance to 5500 or less output 2 Output circuit abnormal 2 Contact YOKOGAWA The reading 1 Span calibration has not been 1 Set electrode sensitivity initialization to ON 1 in service code 08 CHANG Mode and perform calibration again See item f in Sec 5 4 2 Sec 7 3 IM 12F5A1 01E lt 10 Spare Parts and Consumables gt 10 1 10 SPARE PARTS AND CONSUMABLES 10 1 Spare Parts and Consumables List Replacement intervals vary depending on the application 10 2 Spare Parts 10 2 1 Polishing Powder K9088PE Used to remove contamination on the indicator electrode that cannot be removed by automatic cleaning using glass beads ceramic beads One bag of abrasive is provided for the FC400G 10 2 2 Ceramic Beads K9332ZP Name Part No Description Q ty BB isl ep Indicator Electrode Rotating electrode K9332MB Gold electrode 1 Yearly Indicator Electrode Rotating electrode K9334JP Gold alloy indicator electrode 1 Yearly Counter Electrode K9332MK Silver chloride electrode 1 At the time of damage Ceramic Beads K9332ZP For cleaning general type indicator 1 Yearly electrode 2 bags Glass Beads K9332ZJ For cle
109. reduced by loosening screws fixing pulley to driven shaft is not noticeable If operation is still not satisfactory replace motor and gear head Replacement procedure Replacement of motor and gear head should in principle be carried out by Yokogawa service If you want to do it yourself the procedure is as follows e In principle replace motor and gear head at the same time as periodic replacement of other parts Replace complete motor assembly consisting of both motor and capacitor e When replacing motor assembly and gear head first remove motor mounting plate from base There are no special cautions relating to removal of or reassembly of motor assembly and gear head however the parts such as electrode brushes and drive belt removed when removing motor from mounting plate should be carefully reassembled referring to Sec 8 2 1 through Sec 8 2 3 so as not to make any mistakes in reassembly IM 12F5A1 01E lt 9 Troubleshooting gt 9 1 9 TROUBLESHOOTING 9 1 When lt failure gt is Indicated Daily maintenance for maintaining good FC400G operation is described in Chapter 8 this chapter sets forth how to maintain the FC400G in the event of error 9 1 1 Indication of Error Message or Error Code Types of lt failure gt and respective error messages error codes are listed in Table 9 1 e Errors occurring during Measurement If error occurs during measurement the LCD displays an error message Err and 7 The FC
110. rine In general there is no practical problem with span calibration using the sampling method The sampling method takes less effort than the standard solution method Note that the electrode sensitivity is required to be initialized at start up or when performing calibration immediately after the indicator electrode is replaced The electrode sensitivity can be initialized by setting the service code 08 to 1 for initialize electrode sensitivity However calibration after initializing the electrode sensitivity is performed unconditionally Before performing span calibration be sure to confirm that the electrode mechanism block has been placed back into the measuring tank and is ready for measurement Note To initialize the electrode sensitivity press the key when CHANGE is displayed in the message display when entering the lt CAL gt mode When NO CHGN is displayed press the key to display CHANGE and then press the key Span Calibration Using Sampling Method Span calibration using the sampling method can be performed as follows Note Before performing span calibration confirm that the electrode does not remain exposed to the air as after zero calibration and the electrode rotates normally in the measuring tank Start span calibration at the point when zero calibration using the method in Sec 7 2 1 or 7 2 2 is finished and SPAN is displayed in the message display Note When calibration descr
111. ring Principle of FC400G Free Available Chlorine Analyzer The FC400G free available chlorine analyzer applies the polarographic method using a rotating electrode as the measuring principle to measure free available chlorine existing in the form of chlorine CI hypochlorous acid HCIO and hypochlorite ions CIO7 The FC400G applies external voltage between the indicator electrode rotating electrode and counter electrode silver chloride electrode to electrolytically reduce free available chlorine and then measures the diffusion current flow during the above voltage application to obtain the concentration of free available chlorine The voltage to be applied is selected from among values in the area where current value remains stable even if the voltage value changes i e the area plateau area where concentration polarization occurs in polarography Since this applied voltage changes according to the diffusion current value the FC400G free available chlorine analyzer performs compensation complying with this change to apply suitable voltage Further this obtained diffusion current value also changes with temperature and the current is automatically corrected using signals from the RTD Pt 1000 Q built in the counter electrode The FC400G free available chlorine analyzer was designed to require minimal maintenance and uses no reagent However it must be understood that there are restrictions on the conditions of the water to be measure
112. ro calibration parameter setting lt lt WASH gt lt AZ CAL gt Mode Wash parameter setting lt WASH gt Mode This mode is not generally used since the standard free available chlorine analyzer has no washing function Use this mode only if the washing function is added to the FC400G for special specifications Therefore T OFF must generally be established Setting for Special Specification of the FC400G is as follows e Washing Parameter Setting Manual Washing Selection To set up various parameters for washing timer select TIMER For manual Washing select START Press the key This starts washing and message display becomes STOP To stop washing re press the key e Washing Timer ON OFF Selection If the washing timer is not used for the standard free available chlorine analyzer always select T OFF Select T ON only when the washing timer is used e Washing Interval Setting when T ON is selected Set washing interval INT H in the range of 0 1 to 24 0 hrs The washing interval is set to 2 0 hrs at factory shipment lt 6 Operation gt 6 9 e Washing Time Setting when T ON is selected Set washing time WT min in the range of 0 1 to 25 0 min The washing time is set to 1 0 min at factory shipment e Releasing Time Setting when T ON is selected Set releasing time RT min time required for eliminating the effects of washing solution in the range of 0 1 to 25 0 min The releasing time is set to 5
113. ro calibration selection WA CA Mode Selects either washing or auto zero calibration For washing select 0 and for auto zero calibration select 1 Shipping time default is 0 8 Code10 Remote range switching ON OFF R RNGE Mode When input exceeds a preset voltage the range is switched Range can be changed Set 1 ON to enable remote range switching Shipping time default is 0 OFF disabled IM 12F5A1 01E T 7 1 7 2 lt 7 Calibration gt 7 1 CALIBRATION Calibration is required to correctly measure free chlorine concentrations using the FC400G Calibration is performed for the zero point and span There are two methods to calibrate the zero point open input circuit and chlorine free water based measurement methods Also there are two span calibration methods sampling and standard solution methods Calibration is performed at start up or when operation is restarted after being stopped for a long period of time Also calibration is performed periodically recommended every month or so during operation This chapter describes the calibration procedure Running in In general calibration requires running in Always run in the FC400G at start up or when it restarts after being temporarily stopped Running in requires first polishing of the indicator electrode Comply with Sec 6 1 4 on how to polish the indicator electrode After polishing install the polished indicator el
114. rround electrode holder and as a temporary measure loosely tighten the two screws in the lengthwise direction 12 Replace plate that keeps dust from drive belt out of driven shaft assembly electrode holder With the two bumps on the plate facing down pass the plate under the driven shaft and index the two bumps with the two holes in the plate mounted in step 11 Then as a temporary measure loosely tighten the two screws that hold it in place 13 Mount the slip ring on the driven shaft Note The driven shaft and slip ring need to be in contact and make a good electrical connection so make sure that they are clean 14 With the drive belt mounted attach pulleys to the drive shaft and driven shaft Note Mount the drive shaft pulley so that it is 0 3 to 0 7 mm from end of the shaft so that drive belt can lie horizontal 15 Adjust drive belt tension and tighten screws that were loosely tightened in 11 and 12 The 1 00 kg spring plate should fit in the hole in the hook part of the driven shaft to pull the hook of 4 N 0 4 kgf horizontal force 16 Mount indicator electrode on driven shaft and check that indicator electrode is not contacting the base Note If the indicator electrode is contacting the base or if the hole in the center of the base and the center of the indicator electrode are not aligned loose the four screws on the motor mounting base and adjust 17 Remount counter electrode reconnect wiring
115. s been calibrated using the open input circuit method close the needle valve at the sample water inlet of the detector and remove the sample water piping from the joint of the measuring tank Set the tubing and hardware so that sample water can be supplied ata flow rate of at least 100 ml min using a head difference or a pump and connect it to the detector at the sample water inlet When zero point has been calibrated using the chlorine free water based measurement method supply standard solution using the hardware used for the zero calibration Measure the free chlorine concentration of the standard solution correctly using manual analysis e g an amperometric titration method The exact free chlorine concentration of the standard solution changes over time Perform the operation in item 5 immediately after the manual analysis is finished Enter the obtained value in the data display and perform span calibration Confirm that the obtained value has been entered correctly and press the key This causes the mg L or ppm indication to blink during calibration operation When the span calibration is completed normally CAL END appears If an error occurs during calibration operation END E5 or END E7 is displayed in the message display When this message is displayed take countermeasures referring to Sec 7 4 Reattach the tubing to the detector Open the needle valve to allow the sample water to flow Adjust the aperture
116. s provided for the FC400G The same applies to glass beads K9332ZJ used in to decrease influence of combined chlorine insensitive version IM 12F5A1 01E 10 2 lt 10 Spare Parts and Consumables gt 10 2 3 Indicator Electrode K9332MB The indicator electrode is always polished with ceramic beads it gradually wears and ultimately becomes unusable This is the primary factor determining the life of the electrode If the electrode does not become defective owing to any other problem it will generally last for at least three to four years The abrasion based life may be used as a guidance in providing for indicator electrode replacement However recommended practice is to keep one spare always available since the electrode could be inadvertently damaged or otherwise become defective The same applies to gold alloy indicator electrode K9334JP used in combined chlorine insensitive version Note Refer to the following cool storage requirements for electrically conductive silicon grease for indicator electrode Applying Electrically conductive Silicon Grease to Indicator Electrode The indicator electrode needs to be electrically connected to the driven shaft This is achieved by applying electrically conductive silicon grease to the tapped part of the indicator electrode Before use check that this has been done If not apply silicon grease as follows You can purchase 3 ml tubes of conductive silicon grease from Yokog
117. setting level from measurement mode Next press the key to call SERVC and press the key to enter the service level Then enter a code To return from the service level to the measurement mode in the operation level press the key However if the FC400G is in the hold status transfer to the measurement mode is disabled and the FC400G returns to the lt HOLD gt mode Example MODE In hold status Not in hold status is available MODE In hold status Display changes depend on CODE Cis not available F5 3 5e ai IM 12F5A1 01E lt 5 Key Operation and Display gt 5 7 5 4 Mode Selecting Procedure for Each Level and Mode Content 5 4 1 Mode Selection in the Operation Level lt Measurement mode gt MEASURE MODE lt Operation level gt Set cancel hold l l For the description of the i lt CAL gt mode see item 2 in 5 4 1 l l i For the description of the lt HOLD gt mode see item l ji l 4 in 5 4 1 l For the description of the 1 lt DISP gt mode see item 3 in 5 4 1 l E cee eee ge ee as For the description of the lt CELL gt mode see item 5 in 5 4 1 F5 4 1e ai IM 12F5A1 01E 5 8 lt 5 Key Operation and Display gt 1 lt MEASURE gt Measurement Mode Allows concentration and message indications one of temperature diffusion current applied volt
118. splays terminal operation status on the LED FAIL Lights when contacts operated MAINT WASH CAL Lights in the corresponding mode CELL power applied 5 3 5 3 1 lt 5 Key Operation and Display gt 5 3 Basic Key Operation Key Operation When Indication Blinks If the indication blinks in the operation key indicator in the figure below press the or key to response to the message displayed on the message area in the figure Example 1 Blinking indicating that the FC400G is not yet in the CAL mode YES NO 2 Requesting the D or C key 3 Inquiring whether to enter the CAL mode F5 3 1e ai 5 3 2 Key Operation When gt JLA Ent Indication Blinks if the _J _A_J LENT indication blinks in the operation key indicator data entry is required corresponding to the message displayed in the message area Use the key to shift the blinking along digits in the data area increase the value of a blinking digit using the key and finally set it using the key Example YF rir gt OUTPUT VANI T Not blinking indicating that the FC400G is in the OUTPUT mode 2 Requesting data entry Requesting entry of a concentration value with respect to 100 output F5 3 2e ai IM 12F5A1 01E lt 5 Key Operation and Display gt 5 4 Example of Data setting using the and keys
119. steady state 8 Return the electrode mechanism block in place and firmly tighten the two fixing screws 9 Turn ON the power switch or return the fuse in place to restart operation Calibration After polishing the indicator electrode calibrate the zero point and span in the manner described in Chapter 7 It is recommended that calibration be conducted every month in the initial stage of FC400G operation to determine the degree of contamination on the indicator electrode This may be a guidance for determining appropriate maintenance intervals IM 12F5A1 01E 8 4 lt 8 Maintenance gt 8 1 4 Replacement of Activated Charcoal Filter 8 2 1 Close BV1 and BV2 then rotate filter case to remove see Figure 8 4 1 2 Clean inside of case with brush or the like 3 As illustrated in Figure replace filter with new one 4 Reassemble using the reverse procedure then open BV3 and BV1 to pass water through filter Check that there are no water leaks from filter and piping and no bubbles in drain water 5 Operate for about 20 min then confirm that free available chlorine analyzer reading is near zero 6 Close BV3 and open BV2 ball valve 2 Turn F Filter activated charcoal N Lid held in place by piping Spacer a Filter case a F8 0E ai Figure 8 4 Replacing Activated Charcoal Filter Checking the Electrode Mechanism Block and Replacing Damaged Parts Detector electrode parts such as the mo
120. sure that it rotates smoothly The bearings will be worn gradually and so should be replaced after approximately three years operation Replacement should in principle be performed by Yokogawa Note It is recommended that the O ring Part no Y9115XB in the electrode holder in the driven shaft assembly should also be replaced at the same time 10 2 8 Drive Belt L9804UK This perishes and wears and needs to be replaced after about three years operation 10 2 9 Motor Assembly See CMPL The rotating parts wear and this needs to be replaced after about three years operation 10 2 10Gear Head See CMPL The rotating parts wear and this needs to be replaced after about three years operation 10 2 11 Activated Charcoal Filter Element L9862AY Used when auto zero calibration option is installed It is recommended that the filter be replaced once a year IM 12F5A1 01E Customer Model FC400G Maintenance Free Available Chlorine Analyzer Parts List Item Part No Qty Description 1 1 Converter see page 2 2 1 Detector see page 3 All Rights Reserved Copyright 1991 Yokogawa Electric Corporation CMPL 12F05A01 01E YOKOGAWA oo Subject to change without notice 7th Edition Jun 2011 YK Yokogawa Electric Corporation CONVERTER
121. tact turns ON During Auto zero calibration setup time zero water flows then after the stabilization settling time it reverts to sample water Finally analog output hold lt HOLD gt display and lt FLUSH gt display revert to normal and lt MAINT gt contact output turns OFF Zero filter flushing interval timer is started and stopped as follows Timer is started when IM 12F5A1 01E lt 7 Calibration gt 7 5 e Power is ON and zero filter flushing start conditions are satisfied e Auto zero calibration interval is at least one day and Auto calibration functions are ON e When Auto calibration functions are ON and Auto zero calibration interval is changed to at least one day e When Auto zero calibration is ON and Auto zero calibration interval is at least one day and Wash Auto zero calibration setting is switched to Auto zero calibration When timer are starts counter is reset Counter is stopped when e Zero filter flushing timer is ON and Auto calibration setting is turned OFF e Zero filter flushing timer is ON and Auto zero calibration interval is reduced to less than one day e Zero filter flushing timer is ON and Wash Auto zero calibration setting is changed to Wash AN NOTE 1 During zero filter flushing if Auto zero calibration is started then zero filter flushing is aborted 2 Ifthe zero filter flushing counter reaches its count up setting while the instrument is in auto zero
122. tor assembly and driven shaft assembly have finite life If conditions of use or environment are outside of specifications their life may be shorter than would otherwise be expected Periodically check whether electrode mechanism block is operating normally To check if abnormal or not refer to Main Check List for a simple check whether calibration and the like is abnormal refer to Auxiliary Check List Alternate these checks for best results When such parts that are subject to aging have been operated for their recommended lifetime it is recommended that you replace them even if you feel that there is still life left in them Table 8 2 shows a list of parts that we recommend you to periodically check and replace Table 8 2 Parts recommended for periodic checks and replacement Part Recommended check Recommended interval replacement interval Brush and slip ring 3 months 2 years or if characteristic without range Drive belt 6 months sub 3 months 3 years operation Driven shaft assembly 6 months sub 3 months 3 years operation Motor Assembly gear head 6 months sub 3 months 3 years operation IM 12F5A1 01E 8 2 1 lt 8 Maintenance gt 8 5 Inspecting the Brush and Slip Ring A CAUTION Do not touch the brush except when replacement is performed When the electrode mechanism block cover is removed for example for polishing of the indicator electrode also visua
123. ts such as electrode brushes and drive belt removed when removing motor from mounting plate should be carefully reassembled referring to Sec 8 2 1 through Sec 8 2 3 so as not to make any mistakes in reassembly The terminal board within motor assembly should be set same position of C1 and C2 printed on the plate which wire color of C1 is yellow green and C2 is pink black IM 12F5A1 01E lt 10 Spare Parts and Consumables gt 10 1 10 SPARE PARTS AND CONSUMABLES 10 1 Spare Parts and Consumables List Name Part No Description Q ty Pe opel ee Indicator Electrode Rotating electrode K9332MB Gold electrode 1 Yearly Indicator Electrode Rotating electrode K9334JP Gold alloy indicator electrode 1 Yearly Counter Electrode K9332MK Silver chloride electrode 1 At the time of damage Ceramic Beads K9332ZP For cleaning general type indicator 1 Yearly electrode 2 bags Glass Beads K9332ZJ For cleaning combined chlorine insensitive 1 Yearly type indicator electrode 2 bags 1Q ty Polishing Powder Alumina K9088PE For polishing indicator electrode 1 Brush K9332JX_ Part for electrode mechanism block 1 2 years Slip Ring K9332JZ Part for electrode mechanism block 1 2 years Fuse A1111EF 2A 1 Yearly 1 Driven Shaft Assembly K9334JV Part for electrode mechanism block 1 3 years O Ring Y9115XB Part for electrode mechanism bl
124. tting Operation Data 1csscsssseecseeneeeeeteneenees 6 6 6 3 1 SEUNG E e sitet E A tetany Gunieninie cee 6 6 6 3 2 Setting in the Setting LeVeli sis04 eowsasndaedsasieite ian 6 8 6 3 3 Setting in the Service Level c cccccscesccesecevicevesveceevecesieevesveseevenevieevasvye 6 11 CALIBRATION Rene oer ae ene eo On ee Seer 7 1 7 1 RUNNIN Mea 7 1 7 2 Zero Calibration sessen a EA EAEE 7 1 7 2 1 Method of Zero Calibration using Open Input Circuit Method 7 2 7 2 2 Method of Zero Calibration using Chlorine free Water 7 3 7 2 3 Auto Zero Calibration using Chlorine free chlorine not included WAC eassa dears wenden der adinaraer werner 7 3 7 3 Span Calibration wcccsessceccsesecencesccetccceicveweseetas var scnsceesavatcecoseevsteceeenctondenestesecsveres 7 6 7 3 1 Span Calibration Using Sampling Method 7 6 7 3 2 Span Calibration Using the Standard Solution Method 005 7 7 lt CONTENTS gt vii 7 4 Remedies When Errors Occur in Zero or Span Calibration eee 7 8 7 4 1 If Errors occur during Calibration ccecceeceseteeeeeeeeeeeeeneeteeeeeeeeneee 7 8 7 4 2 Remedies When an Error OCCUIS cececceeeceeeeeeteteeteaeeeeneeetaes 7 8 8 INSPECTION AND MAINTENANCE 2 cccssseeesseeessseeeneeeseseeeesneeenes 8 1 8 1 Inspection and Maintenance Items and Implementation Cycle 5 8 1 8 1 1 Polishing the Indicator Electrode eccecceeceeeeeeeeeeeeeeneeeeeeeeeeeeaes 8 1 8 1
125. turns after the brush has contacted the slip ring Confirm that the brush is in contact with the slip ring by measuring the resistance using a tester After the brush mounting bracket has been located screw in the lock screw and also the brush mounting bracket fixing screws 7 Feed power to the free available chlorine analyzer Confirm that the driven shaft rotates smoothly Also measure the resistance between the brush wiring terminal and the driven shaft using a tester to determine that the resistance value is 500 Q or less 8 Install the electrode mechanism block cover in place Check Maintenance Replacement of Drive Belt When you polish the indicator electrode and remove the electrode mechanism block cover for maintenance check the drive belt as follows once in three months recommended Check for powder from drive belt friction deposited on motor mounting plate and the like As the drive belt ages and the mating of the teeth on the pulley with the teeth on the drive belt worsens the amount of powder deposited increases e When the driven shaft pulley is rotated clockwise or anticlockwise its small play causes the drive pulley to rotate If the drive belt loosens and cannot transmit enough traction the play becomes larger Once in six months you should perform the following checks and maintenance e Check if aging of the drive belt has caused cracking If there is serious cracking replace it e C
126. upplying zero water once in 24 hours to protect the corrosive of the activated charcoal filter The measured value is held HOLD lights and FLUSH blinking is displayed 1 Auto zero calibration is selected 2 Auto zero calibration timer is turned ON 3 Auto zero calibration interval needs to be one day 24 hours or longer refer to Sec 7 2 2 d Plateau Measurement lt PLAT gt Mode Set the initial applied voltage Step applied voltage and step count then give a running command This causes the voltage corresponding to the setting parameters to be applied in turn allowing collection of the plateau characteristic voltage to current characteristic The plateau characteristic obtained can be used as guidance for determining electrode abnormality or the degree of deterioration Note The applied voltage changes during acquisition of the plateau characteristic Therefore when output hold has been canceled pressing the key with HLD OF displayed for lt SET HD gt in item 2 Sec 5 4 2 output changes in accordance with the set output range Utilizing this feature changes in the free chlorine concentration value can be replaced by the status of current change to be output for example to a recorder The output range must be set to an appropriate level in accordance with the plateau characteristics Output of all changes may not be available depending on the applied voltage setting range IM 12F5A1 01E 6 10 lt 6
127. utomatically holding output Pressing the key with HLD OF displayed cancels holding of output When HLD ON is selected select the value immediately preceding hold press key with HD LST displayed or fixed value press key with HD FIX displayed and make setting with HOLD displayed as a hold output value To cancel hold use the hold ON OFF mode in the operation level Note The status selected previously appears first Sa aaa le Enter the fixed value in hold status F5 12 2e ai IM 12F5A1 01E lt 5 Key Operation and Display gt 5 13 c lt WASH gt Wash mode The standard free available chlorine analyzer non reagent type has no washing function this mode is not used Use this mode only when the washing function is provided for special specifications Therefore T OFF status must be generally set In case of special product with washing function perform the operation with the followings Press the key to enter the setting level and press the key to select lt WASH gt Press the key TIMER or START displayed For auto wash press the key at the TIMER display T OFF and T ON options are displayed select T ON to start auto wash For the standard model without auto wash option or to turn auto wash off select T OFF For the timer function set washing intervals INT H unit hr washing time WT min unit min and relieving time RT min unit min
128. y a belt and drives it The signal from this indicator electrode Gear head Brush Cell motor Rotates the indicator electrode Clamp at a constant speed Holds the counter electrode Measuring tank Sample inlet Indicator electrode Note1 Note 1 To decrease influence of combined The combined chlorine insensitive version uses a gold alloy indicator electrode Counter electrode Pt 1000 Q RTD built in silver chloride electrode Drain F4 1e ai Figure 4 1 Detector Parts Names and Functions IM 12F5A1 01E 4 2 lt 4 Parts Names and Operations gt lt Converter gt Keystroke in operation level can be accomplished with the case cover installed Case cover Operation level indicating panel Operation keys Display unit Fixing screws F4 2e ai Figure 4 2 Converter Parts Names with the Cover Closed Setting level indicating panel Setting level Operation level selector switch F4 3e ai Figure 4 3 Converter Parts Names with the Cover Opened IM 12F5A1 01E 4 2 4 2 1 lt 4 Parts Names and Operations gt Operation Modes and Codes Operation with the case cover closed lt Operation with the case cover opened Operation leve MEASURE Mode e When entering
129. zero calibration is turned ON e After the Auto zero calibration interval is changed provided Auto zero calibration is turned ON e When the Wash Auto zero calibration setting is switched to Auto zero calibration 3 The counter timer keeps running regardless of operation mode 4 Auto zero calibration is initiated only in MEAS mode If the counter reaches its count up setting while the instrument is in MAINT mode calibration is cancelled not triggered that time the timer is reset and counting restarts Output hold and Maint contact T2 T3 T4 Wash Auto zero calibration contact output 1 T7 2 3E ai T1 Auto zero calibration interval T2 Auto zero calibration setup time T3 Auto zero calibration time varies depending on conditions T4 Auto zero stabilization settling time of sets stability determination parameter 1 WASHICAL lamp blinks 5 2 Display Content on the Display Unit and W1 W2 of Figure 3 4 are operated Zero filter flushing Under the following condition Zero filter flushing function will be activated automatically 1 Wash Auto zero calibration set to Auto zero calibration 2 Auto zero calibration timer turned ON and 3 Auto zero calibration interval set to one day or longer Zero filter flushing interval and sequence Interval is fixed once in 24 hours When flushing starts analog output is held lt HOLD gt lights lt FLUSH gt flashes and the lt MAINT gt con

Model FC400G Free Available Chlorine Analyzer (Non

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